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Z O N E L I N E ® PA C K A G E D T E R M I N A L A I R C O N D I T I O N E R S

Architects and Engineers Design Data Manual

Featuring The NEW 5500 Series

We bring good things to life.

Quick Reference

2500 Series Cooling with Electric Heat

MODEL NUMBER

AZ25E07D2* AZ25E07D3* AZ25E09D2* AZ25E09D3* AZ25E09D5* AZ25E12D2* AZ25E12D3* AZ25E12D5* AZ25E15D2* AZ25E15D3* AZ25E15D5* AZ25E07E3* AZ25E07E4* AZ25E09E3* AZ25E09E4* AZ25E09E5* AZ25E12E3* AZ25E12E4* AZ25E12E5* AZ25E15E3* AZ25E15E4* AZ25E15E5*

COOLING (Btuh)

7100/6900 7100/6900 9000/8800 9000/8800 9000/8800 11700/11500 11700/11500 11700/11500 14600/14300 14600/14300 14600/14300 7100 7100 9000 9000 9000 11700 11700 11700 14600 14600 14600

Cooling Watts

600/585 600/585 785/765 785/765 785/765 1075/1055 1075/1055 1075/1055 1520/1490 1520/1490 1520/1490 600 600 785 785 785 1075 1075 1075 1520 1520 1520

EER

11.8/11.8 11.8/11.8 11.5/11.5 11.5/11.5 11.5/11.5 10.9/10.9 10.9/10.9 10.9/10.9 9.6/9.6 9.6/9.6 9.6/9.6 11.8 11.8 11.5 11.5 11.5 10.9 10.9 10.9 9.6 9.6 9.6

Electric Heat (Btuh)

8600/7100 11700/9600 8600/7100 11700/9600 17000/13900 8600/7100 11700/9600 17000/13900 8600/7100 11700/9600 17000/13900 8600 12600 8600 12600 17000 8600 12600 17000 8600 12600 17000

Electric Heater Watts

2550/2090 3450/2820 2550/2090 3450/2820 5000/4090 2550/2090 3450/2820 5000/4090 2550/2090 3450/2820 5000/4090 2550 3700 2550 3700 5000 2550 3700 5000 2550 3700 5000

Electric Heat Amps

11.0/10.0 15.0/13.6 11.0/10.0 15.0/13.6 21.7/19.7 11.0/10.0 15.0/13.6 21.7/19.7 11.0/10.0 15.0/13.6 21.7/19.7 9.6 14.0 9.6 14.0 18.9 9.6 14.0 18.9 9.6 14.0 18.9

Min. Circuit Protection (Amps)

15 20 15 20 30 15 20 30 15 20 30 15 20 15 20 30 15 20 30 15 20 30

2500 and 3500 Series Control Panel

3500 Series Heat Pump with Backup Resistance Heat

MODEL NUMBER

AZ35H07D2* AZ35H07D3* AZ35H09D2* AZ35H09D3* AZ35H09D5* AZ35H12D2* AZ35H12D3* AZ35H12D5* AZ35H15D2* AZ35H15D3* AZ35H15D5* AZ35H07E3* AZ35H07E4* AZ35H09E3* AZ35H09E4* AZ35H09E5* AZ35H12E3* AZ35H12E4* AZ35H12E5* AZ35H15E3* AZ35H15E4* AZ35H15E5*

COOLING (Btuh)

7100/6900 7100/6900 9000/8800 9000/8800 9000/8800 11700/11500 11700/11500 11700/11500 14600/14300 14600/14300 14600/14300 7100 7100 9000 9000 9000 11700 11700 11700 14600 14600 14600

Cooling Watts

600/585 600/585 785/765 785/765 785/765 1075/1055 1075/1055 1075/1055 1520/1490 1520/1490 1520/1490 600 600 785 785 785 1075 1075 1075 1520 1520 1520

EER

11.8/11.8 11.8/11.8 11.5/11.5 11.5/11.5 11.5/11.5 10.9/10.9 10.9/10.9 10.9/10.9 9.6/9.6 9.6/9.6 9.6/9.6 11.8 11.8 11.5 11.5 11.5 10.9 10.9 10.9 9.6 9.6 9.6

Reverse Cycle Heat (Btuh)

6400/6200 6400/6200 8400/8200 8400/8200 8400/8200 10900/10700 10900/10700 10900/10700 13400/13200 13400/13200 13400/13200 6400 6400 8400 8400 8400 10900 10900 10900 13400 13400 13400

COP

3.5/3.5 3.5/3.5 3.5/3.5 3.5/3.5 3.5/3.5 3.3/3.3 3.3/3.3 3.3/3.3 3.1/3.1 3.1/3.1 3.1/3.1 3.5 3.5 3.5 3.5 3.5 3.3 3.3 3.3 3.1 3.1 3.1

Electric Heat (Btuh)

8600/7100 11700/9600 8600/7100 11700/9600 17000/13900 8600/7100 11700/9600 17000/13900 8600/7100 11700/9600 17000/13900 8600 12600 8600 12600 17000 8600 12600 17000 8600 12600 17000

Electric Heater Watts

2550/2090 3450/2820 2550/2090 3450/2820 5000/4090 2550/2090 3450/2820 5000/4090 2550/2090 3450/2820 5000/4090 2550 3700 2550 3700 5000 2550 3700 5000 2550 3700 5000

Electric Heat Amps

11.0/10.0 15.0/13.6 11.0/10.0 15.0/13.6 21.7/19.7 11.0/10.0 15.0/13.6 21.7/19.7 11.0/10.0 15.0/13.6 21.7/14.7 9.6 14.0 9.6 14.0 18.9 9.6 14.0 18.9 9.6 14.0 18.9

Min. Circuit Protection (Amps)

15 20 15 20 30 15 20 30 15 20 30 15 20 15 20 30 15 20 30 15 20 30

LEGEND COP ­ Coefficient of Performance EER ­ Energy Efficient Ratio * ­ Covers All Model Versions

All Units are 60 hertz single phase. Dual rated 230/208 volt units are shown with ratings separated by "/". Units with one rating are 265 volt units.

2

Quick Reference

5500 Series Heat Pump with Backup Resistance Heat

MODEL NUMBER

AZ55H07DA* AZ55H09DA* AZ55H12DA* AZ55H15DA* AZ55H07EA* AZ55H09EA* AZ55H12EA* AZ55H15EA*

COOLING (Btuh)

7100/6800 9000/8800 11800/11600 14700/14400 7100 9000 11800 14700

Voltage 60 hz 1-phase

230/208 230/208 230/208 230/208 265 265 265 265

Cooling Watts

590/565 785/765 1085/1065 1470/1440 590 785 1085 1470

EER

12.0/12.0 11.5/11.5 10.9/10.9 10.0/10.0 12.0 11.5 10.9 10.0

COP

3.5/3.5 3.5/3.5 3.3/3.3 3.1/3.1 3.5 3.5 3.3 3.1

Reverse Cycle Heat (Btuh)

6400/6200 8400/8200 10900/10700 13400/13200 6400 8400 10900 13400

5500 Series Control Panel

LEGEND COP ­ Coefficient of Performance EER ­ Energy Efficient Ratio * ­ Covers All Model Versions

Zoneline® Chassis Nomenclature

The Zoneline chassis is identified by a model number defining the type of unit, cooling capacity, electrical information and optional features included on the unit. When specifying or ordering the Zoneline chassis use of this nomenclature will assure receiving the correct unit.

Example

A A Z Z 2 5 5 5 E H 0 1 9 2 E D 4 A P D

Zoneline®

Packaged Terminal Chassis

Special Features

B - Base Unit C - Corrosion Treated D - Internal Condensate Removal (ICR) System (Heat Pump Models Only) P - Dry Air 25

Chassis Series

25 - Deluxe Line Cool/Electric Heat 35 - Deluxe Line Heat Pump

5500 Universal Power Connection

55 - Premium Line Heat Pump (see Premium Series Models - see page 53)

Unit Type

E - Cooling with Electric Resistance Heat H - Heat Pump with Electric Resistance Heat

2500, Dry Air 25 & 3500 Numeric Designator of Heater Size

230/208 Volt 2 - 2.55/2.09 kW 3 - 3.45/2.82 kW 5 - 5.0/4.09 kW 265 Volt 3 - 2.55 kW 4 - 3.7 kW 5 - 5.0 kW

Nominal Cooling Capacity

07 - 7,000 BTUH Cooling 09 - 9,000 BTUH Cooling 12 - 12,000 BTUH Cooling 15 - 15,000 BTUH Cooling

Voltage/Phase/Frequency

D - 230/208 Volt E - 265 Volt Single Phase 60 Hz Single Phase 60 Hz

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The Zoneline 2500, 3500 and 5500 Series have incorporated changes suggested by customers and enhancements by GE's Technology team:

Auto Heat/Auto Cool settings to reduce operating sound level while increasing occupant comfort Ability to connect to wall thermostat or Central Desk Control without additional interface module 7-step temperature limiting with separately selectable heating and cooling limits Transfer Fan interface - enables a fan mounted in the wall to operate in conjunction with the unit fan (fan, wiring and relay are field supplied) - "Smart Fan" fan cycle/fan continuous operation to increase room occupant comfort - Easier installation of chassis in existing wall cases See the "Features and Benefits" section for in depth explanation of these changes and the industry leading features of the GE Zoneline retained from the previous series. -

The Deluxe 2500 Series Zoneline Models Includes The "Dry Air 25" Models Which Remove 25% More Moisture Than Other Zoneline Models. Deluxe Dry Air 25 Models

Cooling With Resistance Heat · Removes 25% More Moisture than other Zoneline Models, up to 2.7 Additional Gallons Per Day · Cool and Dry Air in Less Time than Standard Zoneline Models · Heat Pipe is a Separate Sealed Refrigerant System - No Mechanical Parts - No Special Maintenance Required · Helps Maintain Lower Relative Humidity In Rooms · Maintains Comfort at Slightly Higher Room Temperatures - Reduces Operating Costs - Provides Comfort Without Overcooling · Corrosion Treatment is Standard · Excellent Choice for Humid Climates · Available in 7000, 9000 and 12000 BTU Sizes The Dry Air 25 system, a heat pipe, is a hermetically sealed heat transfer surface installed in a "saddlebag" configuration around the indoor (evaporator) coil of the Zoneline. This coil arrangement will transfer heat from the front coil of the saddlebag to the rear coil without power consumption. This assembly uses R-22 as the refrigerant and is not connected to the regular Zoneline refrigerant circuit. As warm humid air is pulled through the pre-cool (front) section of the heat pipe, the heat removed from the air is absorbed by the refrigerant, causing the refrigerant to change to a gas and flow to the re-heat (rear) section of the heat pipe. The air leaving the pre-cool section of the heat pipe is cooler and at a higher relative humidity level than the room air. The pre-cooled air is further cooled as it passes through the evaporator; consequently, the relative humidity increases allowing the evaporator coil to remove more moisture. When the cold air from the evaporator comes in contact with the re-heat section of the heat pipe, the heat that was removed by the pre-cool section is added back to the air and the refrigerant in the heat pipe condenses and flows back to the indoor coil. The air discharged into the room by this process is much drier, creating a more comfortable room condition. The Newest Innovation from GE... The Dry Air 25 Models center around GE's exclusive use of the patented Dinh® Dehumidifier Heat Pipe from Heat Pipe Technology, Inc. This innovative NASA spin-off technology enables Dry Air 25 to remove 25% more moisture from the air than other leading manufacturers' packaged terminal air conditioners. This helps maintain room comfort at a higher room temperature, reducing operating costs. The Dry Air 25 keeps a room cool and dry, and this is the most important benefit when it comes to the occupant of the room - hotel guests, apartment residents, students... In a hot, humid climate, getting away from the humidity is just as important as the heat, and the Dry Air 25 is the perfect solution. The dehumidification of the Dry Air 25 has been verified by the same ARI test conditions that standard units are rated under. A list of customers using Dry Air 25 is available from GE.

COMPARISON OF DRY AIR 25 DEHUMIDIFICATION*

GE Dry Air 25

®

GE 2500 Series Zoneline

Removes

Amana

25%

More Moisture

Carrier

*Based on 12,000 BTU Units. NOTE: The Dry Air 25 models include all features of the 2500 series.

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Table of Contents

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Mini-Specs 2500 and 3500 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Mini-Specs 5500 and Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 The 2500/3500/5500 and Dry 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 The Zoneline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Benefits Features Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 Auxiliary Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Central Desk Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remote Thermostat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Multiple Unit Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Heat Pumps and Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20 Installation and Dimensions Introduction to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Application Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Case Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Wall Case/Sub-Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - 33 Condensate Disposal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 36 Ducted Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 39 Exterior Grilles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Product Data Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 43 Maximum Connected Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Cooling / Heat Pump Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Latent System Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Normal Yearly Operating Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 50 Product Specifications Suggested Bid Form Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - 53 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 55 Complete Accessory List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 General Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 58 Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Back Cover - Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Important Notice

Equipment used as a primary source for heating or cooling is an integral part of the building in which it is installed. Proper application is essential for satisfactory performance over a wide range of operating conditions. It is strongly recommended that a professional engineer determine proper application. If this unit is a replacement unit, its specifications and performance may differ from those of the unit it is replacing. For that reason, we again strongly recommend that a professional engineer determine proper application. 5

Introduction

This manual is designed to provide product, performance and application information to our customers and their architects and engineers for use in selection and design of a zonal comfort control system utilizing GE Zoneline® Packaged Terminal Air Conditioners (PTAC) and Packaged Terminal Heat Pumps (PTHP). GE Zoneline® PTACs and PTHPs are self-contained units designed for through-the-wall installations in hotels, motels, apartments, hospitals, nursing homes and add-on rooms. Zonelines provide individual room or zone control in both cooling and heating operation. There is a model for practically every application, ranging in cooling capacities from 7,100 to 14,700 BTUH and heating capacities from 6,400 to 13,400 BTUH in heat pump operation. See page 54 for resistance heaters available. The Zoneline offers a two tier lineup; the Deluxe Line - the 2500 Series with electric resistance heat, including the Dry Air 25 Models with enhanced dehumidification for hot and humid climates, and the 3500 Series heat pump; the Premium Line - the 5500 Series heat pump.

· Economical Installation

· No ductwork necessary · No mechanical equipment rooms or pipes required for heating/cooling units · Replacement units fit existing 42" wide by 16" high wall cases

· Quiet Operation

· Auto Fan operates unit at lowest, quietest fan speed when possible to reduce the sound from the unit · Indoor double cut-off scroll: two fan motor 2500 and 3500 Series units · Indoor cross-flow blower: 2 fan motor 5500 Series units

· Energy-Saving Operation

· Units in unoccupied areas may be turned off · Designed for efficient cooling operation - EERs from 9.6 to 12.0 · Efficient heat pump units - COPs from 3.1 to 3.5 · Extended heat pump operation without sacrificing room comfort

Deluxe Line Standard Features:

· Freeze SentinelTM · Indoor Coil Frost Control · Central Desk Control Interface · Standard Remote Thermostat Control Capability · Random Restart · Electronic Temperature Limiting · "Smart Fan" Fan Cycle/Continuous Control · Transfer Fan Interface · Separate Indoor and Outdoor Fan Motors · Room Occupancy Sensor Interface NOTE: The Dry Air 25 models include all features of the 2500 series.

· Ease of Maintenance

· Permanently lubricated fan motors · Upfront lift out filters · Air Discharge area is easily accessed for cleaning Deluxe Series · Slide out chassis for easy access if service is required

· Heat Pump Operation (Defrost Termination)

After the heat pump models have switched to resistance heat they will change back to heat pump operation as the outdoor temperature rises - the 3500 series returns to heat pump operation at 37°F outdoor coil temperature, and the 5500 series returns to heat pump operation at 32°F outdoor air temperature.

Premium Line Standard Features:

· All the Standard Features of the Deluxe Line · Exclusive Simultaneous Heat Pump and Resistance Heat Operation (when needed) · Exclusive Reverse Cycle Defrost to Increase Heat Pump savings · Touch Pad Controls with Digital Temperature Readout

Advantages of the GE Zoneline® System:

· Flexible Application

· May be installed flush to finished floor to 3" from the ceiling · 7,100 to 14,700 BTUH units in same physical size · Deluxe 2500 and 3500 Series may be ducted to condition more than one room · Compatible with Class 2 Remote Thermostat Control · Compatible with 2 wire CDC and many Energy Management systems

6

The Zoneline® System

The typical Zoneline installation consists of the wall case (or sleeve), chassis, and exterior grille. Some installations may use a sub-base for support of the unit or for ease of electrical connections. Each of the components should be the standard products offered by GE or, in the case of the exterior grille, approved by GE Applications Engineering. Use of components not specifically designed or approved for use with the Zoneline can result in unsatisfactory operation and can be the cause of failure not covered by the warranty.

Components of the Zoneline® System

Wall Case RAB71 (Steel-Insulated) RAB77 (SMC - Molded) Wall Case Options (See page 23)

Chassis RAG67 (shown) Grill Options (See page 40)

Room Cabinet

Deluxe Series shown

Typical Installation

Power Connection Kit (not shown) (required on Premium Series) See pages 42 - 43

Optional Accessories of the Zoneline® System

Chaseway

RAK6052 Duct Adapter (For Deluxe Series)

RAK204D20 Sub-Base (shown)

See pages 23 and 33 for information on electrical sub-bases and chaseway.

RAK601/602 (For Deluxe Series) Duct Extension, Register and Trim Flange

7

Zoneline® Features

AZ 2500 Optional 9.6 - 11.6 N/A Page 54 --

Model Series

AZ 3500 N/A 9.6 - 11.6 3.1 - 3.5 -- Std. Pages 19, 55 -- 2 Stage -- Standard Standard -- Passive -- Standard -- -- -- Standard 2 Standard Standard Standard "Smart Fan" Standard Standard Included Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard RAK6052 Optional Optional AZ 5500 N/A 10.0 - 12.0 3.1 - 3.5 -- --

Enhanced Dehumidification - Dry Air 25 Cooling EER Range (230 Volts/265 Volts) Heating COP Range (230 Volts/265 Volts) Heat Source - Electric Resistance Heat Heat Source - Heat Pump With Backup Resistance Heat Heat Source - Heat Pump With Selectable Full Time or On Demand Simultaneous/ Supplemental Resistance Heat Staged Heating Universal Heater Automatic Emergency Heat Highly Featured Microprocessor Controls Electric Resistance Heat Lock-Out (above 46°F) Heat Pump Defrost System Unit Diagnostics Quick Heat Recovery Service Indicator Touch Controls (Tactile Controls) Electronic Temperature Selection (Slews Up & Down) with Digital Display Rotary Control Knobs Fan Motors - Permanently Lubricated 2 Speed Outdoor Fan Indoor Fan Speed Selections - AUTO/HIGH Fan Only Setting - HIGH/LOW Fan Cycle Switch Rotary Compressor Automatic Compressor Restart Delay Power Connection Cord Freeze SentinelTM Indoor Coil Frost Control Transfer Fan Connections 7 Step Electronic Temperature Limiting Energy Management System Interface Remote Control Capability With Wall Mounted Thermostat Central Desk Control Capability With Load Shedding Option Reversible Indoor Air Louvers 40°/50° Up-Front Filters Easy Clean Air Discharge Area Concealed Manual Vent Control Ducted Installation Capability Corrosion Treated Internal Condensate Removal (ICR) Factory Installed Option. Cannot be used in Corrosion Areas.

-- -- -- -- Standard -- -- -- -- -- -- -- Standard 2 Standard Standard Standard "Smart Fan" Standard Standard Included Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard RAK6052 Optional N/A

Std. Pages 20, 55 3 Stage Standard Standard Standard-Plus Standard Reverse Cycle Standard Standard Temp Display Blinks Standard Standard -- 2 Standard Standard Standard "Smart Fan" Standard Standard UPC* Standard Standard Standard Standard Standard Standard Standard Standard Standard -- Standard -- -- Optional

*UPC - Universal Power Cord Connection (See pages 42, 43 and 55) **265 volt units must be connected in a manner to meet National Electrical Code and all local codes.

8

Features and Benefits

Standard Physical Dimensions

GE has maintained the same dimension since 1961- 42" wide x 16" high x 13 3/4" deep. Replacement of older units made easy.

Electric Resistance Heat Lock-Out

To maximize the savings of the heat pump operation, the 5500 series Zoneline does not utilize the resistance heater when the outdoor temperature is above 45°F during normal operation. The resistance heat is used in the Quick Heat Recovery feature.

Weather Protected Electrical Components

Vital electrical components are protected from the weather by locating them on the indoor side of the weather barrier.

Automatic Emergency Heat Heat Pump Defrost Systems

See pages 19 and 20 for discussion of heat pump operation and defrost systems.

Weather-Resistant "Superseal"

Properly installed unit in undistorted case keeps air leakage to a minimum. 7 CFM air infiltration with 25 MPH wind on non-ICR units 10 CFM on units with ICR. Industry specification is 19 CFM of air infiltration.

High Temperature Heat Pump Operation Protection

Automatically protects the compressor if heat pump is operated with high outdoor temperatures. Shuts the outdoor fan off if the indoor coil gets too hot during heat pump operation to prevent damage to the compressor.

Heater Sizes to Meet Room Requirements

2500 and 3500 Series 230/208 Volt · 15 Amp - 2.55/2.09 KW · 20 Amp - 3.45/2.82 KW · 30 Amp - 5.0/4.09 KW 265 Volt · 15 Amp - 2.55 KW · 20 Amp - 3.7 KW · 30 Amp - 5.0 KW 5500 Series have universal heater ­ resistance heat output is determined by power connection kit. 230/208 Volt · 15 Amp - with RAK3152 - 2.55/2.09 KW · 20 Amp - with RAK3202 - 3.45/2.82 KW · 30 Amp - with RAK3202 - 5.0/4.09 KW 265 Volt · 15 Amp - with RAK5152 - 1.7 KW · 15 Amp - with RAK5172 - 3.0 KW · 20 Amp - with RAK5302 - 3.7 KW · 30 Amp - with RAK5302 - 5.0 KW

Quick Heat Recovery - Heat Pump Units

When the unit operation is changed from STOP or COOL to HEAT, the electric resistance heaters are used to warm the room to the thermostat set point. This provides faster room temperature increase for greater guest comfort.

Unit Diagnostics

The 5500 series has a dip switch that activates each of the various components of the unit to operate briefly. This enables the service technician to determine if individual components are functioning properly.

Service Indicator

On the 5500 series, the microprocessor detects a compressor malfunction, the digital temperature display will blink. If the malfunction occurs during cooling operation, the indoor fan will operate to circulate room air. If in the heating mode, the unit will automatically switch to resistance heat so the room occupant will not be uncomfortable. The blinking display is an alert that the unit is operating in the more expensive resistance heat mode.

Unit Controls

2500 and 3500 series - rotary knobs for temperature and operation selection 5500 series - touch pad controls with digital readout of temperature set point

Fan Motors - Permanently Lubricated

All units have two fan motors for quiet operation and maximum operating efficiency. Motors are permanently lubricated to reduce maintenance and totally enclosed to keep dirt and water out of the motor windings.

Highly Featured Microprocessor Controls

Microprocessor controls are programmed to interface with the temperature sensors to maximize comfort conditions for the room occupant and provide the outstanding features on the units. Thermistors are used to sense small changes in temperature to give excellent room control and to allow the microprocessor to monitor and react to changing conditions.

2 Speed Outdoor Fan

The unit automatically selects the most efficient speed for the outdoor fan. The operating sound level is lower when the outdoor fan can operate in low speed yet there are situations where it must operate in high speed - the unit changes the fan speed automatically.

9

Indoor Fan Speed Selections - AUTO/HIGH

Unit may be operated in HIGH HEAT, AUTO HEAT, HIGH COOL or AUTO COOL. In "AUTO", the indoor fan will be in low speed for quieter operation if the room temperature is within 1.8°F of the set point, or in high speed if the room temperature is more than 1.8°F away from the set point. This feature allows the greatest control over the room temperature while reducing the operating sound level.

Indoor Coil Frost Control

Prevents indoor coil from freezing and causing complaints due to lack of cooling. Frost can form on the indoor coil when the unit is operated in cooling when outdoor temperatures are low. The unit automatically shuts the compressor off until the indoor coil temperature warms to the point where frosting will no longer occur.

Fan Only Setting - HIGH/LOW

The unit provides the option of selecting either HIGH or LOW speed for Fan Only operation.

Transfer Fan Interface

24 VAC terminals are provided to operate a relay to control a fan mounted in a wall to move conditioned air into another space. Transfer fans and their controlling relays are field supplied.

Fan Cycle Switch - "SmartFan"

Unique "SmartFan" allows unit to operate in fan continuous in cooling operation and fan cycle in heating to provide better guest comfort. This eliminates complaint of cold air draft during heating operation. This feature eliminates need of changing fan cycle switch seasonally. "SmartFan" settings are controlled by separate fan cycle/ continuous switches for heating and cooling modes.

Electronic Temperature Limiting

7 independent programmable heating temperature limits and 7 independent programmable cooling temperature limits. Wide selection of limits eliminates need to reset the limits seasonally.

Heating Temperature Limits

65 70 Lowest Cool 60 64 72 74 76 78 80 Highest Heat 85

Automatic Compressor Random Restart

In the event of a power failure all compressors attempting to restart immediately when power is restored can result in a power surge that can cause another power interruption. The microprocessor in the Zoneline units have a random restart logic system that prevents all units from starting at the same time.

Cooling Temperature Limits

66 68 70 72 74 76

Limits are set by dip switches on auxiliary control panel.

Rotary Compressor

Smoother operation for quiet, dependable service. GE has used rotary compressors since 1961.

Remote Control Capability with Wall Mounted Thermostat

See pages 15 - 18

Compressor Restart Delay

Zonelines are designed to provide a minimum of three minutes of compressor off time to allow refrigerant pressures to equalize before restarting, to prevent damage to compressor. Zonelines are also designed to provide a minimum of three minutes of compressor run time to prevent room occupant disturbance due to short cycling air conditioner.

Central Desk Control Capability

See page 14

Energy Management System Interface With Load Shedding Option

All units have a switch on the auxiliary control panel to allow the indoor fan to continue operating if the unit is connected to an Energy Management System that shuts off compressor or heater operation. By allowing the indoor fan to run when the heater or compressor is shut off by the Energy Management System, the guest is less likely to realize the operation of the unit has been altered. This helps to reduce peak energy demand loads without disturbing the room occupant.

Freeze SentinelTM

Detects low room temperature and turns on heater to help protect against damage by freezing temperature in the room. Heater automatically turns on at 41°F, warms indoor thermistor temperature to 46°F, and shuts off. Freeze Sentinel may be turned off by dip switch on auxiliary control.

Reversible Indoor Air Louvers

Allows air to be directed into room at 40 or 50 degree angles to provide better air distribution. Angle is changed by removing room front and screws holding louver in place and rotating louver section 180°.

10

Up-Front Air Filters

Two up-front filters, easy to remove and reinstall, may be cleaned without removing the room front. Clean by brushing, vacuuming, or back flushing under faucet or shower head.

Internal Condensate Removal (ICR)

See page 34 for a discussion of the Internal Condensate Removal system available on the 3500 and 5500 series heat pumps.

Enhanced Dehumidification

Moisture removal is an important function of an air conditioner. People are more comfortable at higher temperatures when the humidity level is relatively low. Air conditioners operate with less energy consumption when the room temperatures are set higher. The GE Zoneline 2500 series with the Dry Air 25 heat pipe application removes 25% more moisture than our base 2500 series unit - which is already an industry leader among the major brands of Packaged Terminal Units. The GE Zoneline Dry Air 25 chassis is the only unit available with the application of the patented Dinh Dehumidifer Heat Pipe under license from Heat Pipe Technology, Inc. Customers who are using the Dry Air 25 report a fresher smelling room as a result of the lower humidity levels - as well as lower operating costs.

Easy Clean Air Discharge Area

2500 and 3500 series units have an out-of-sight vertical protective screen over the indoor fan. This allows easy cleaning of air discharge area by simply removing room front and wiping clean. There is no screen directly below discharge louver to trap unsightly dirt and debris where it may be seen by room occupants.

Concealed Manual Vent Control

Vent can allow up to 70 CFM of outside air to enter the room (40 CFM on 7100 BTUH unit; 65 CFM on 9000 BTUH unit; 70 CFM on 11700 BTUH and 14600 BTUH units). Greater amounts of air can be introduced if the room has an exhaust fan. An open vent door brings unconditioned outdoor air into the room, increasing heating and cooling costs. Positive vent door closure prevents accidental opening and unwanted air infiltration. Shipping hardware may be left on the door for a permanent closure.

Locking Door Kit

RAK8022 - A door with a lock, that replaces the standard control cover door to prevent unauthorized changing of control setting, is offered as an accessory.

Corrosion Protection (Optional)

2500 and 3500 series units may be ordered with special protection to better withstand the damage by salt air and salt water in seacoast areas. Corrosion protected chassis is standard on Dry Air 25 models. Heat Pump units with ICR are not available with corrosion protection and should not be installed in seacoast or corrosive environment. Units installed in corrosive areas should be examined and cleaned more frequently than normal installations.

11

Auxiliary Control Switches

These switches are located behind the room cabinet under the control panel.

2500 and 3500 Series

Switches (1) Description ALL I2R Heat pump override - Down - heat pump operation Up - resistance heat only (not used on 2500 series) (2) C:FAN Fan control for cooling operation - Down - Fan Continuous Up - Fan Cycle (3) H:FAN Fan control for heating operation - Down - Fan Cycle Up - Fan Continuous (4) CLASS 2 Remote Thermostat Mode Down - Unit Control Up - Remote Thermostat (5) LOAD SHED Load Shedding when connected to Central Desk Control System Down - Fan shuts off with unit Up - Fan under "Smart Fan" settings (6) FREEZ S Freeze Sentinel Override - Down - Freeze Sentinel ON Up - Freeze Sentinel OFF (7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode (8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control Up - Occupancy Sensor Connected Temp L1 - Temp L3 Cooling temperature limiting (See table at bottom of page) Temp L4 - Temp L6 Heating temperature limiting (See table at bottom of page)

Cooling and Heating temperature limits are set independently. Temperature limiting switches in factory set down position except as noted.

Cooling Temperature Limits

Switches Up LC Minimum Temperature Switches Up LC Minimum Temperature NONE 60 6 65 1 64 4,6 70 1,2 66 4,5,6 72 2 68 5,6 74 2,3 70 5 76 1,2,3 72 4,5 78 1,3 74 4 80 3 76 NONE 85

Heating Temperature Limits

12

Auxiliary Control Switches

These switches are located behind the room cabinet under the control panel.

5500 Series

Heat pump override - Down - Heat pump operation Up - Resistance heat only (2) C:FAN Fan control for cooling operation - Down - Fan Continuous Up - Fan Cycle (3) H:FAN Fan control for heating operation - Down - Fan Cycle Up - Fan Continuous (4) CLASS 2 Remote Thermostat Mode Down - Unit Control Up - Remote Thermostat (5) LOAD SHED Load Shedding when connected to Central Desk Control System Down - Fan shuts off with unit Up - Fan under "Smart Fan" settings (6) FREEZ S Freeze Sentinel Override - Down - Freeze Sentinel ON Up - Freeze Sentinel OFF (7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode (8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control Up - Occupancy Sensor Connected Temp L1 - Temp L3 Cooling temperature limiting (See table at bottom of page) Temp L4 - Temp L6 Heating temperature limiting (See table at bottom of page) BOOST Turns on supplemental heater with heat pump when outdoor temperature is below 45°F DIAGNOS Used by service technician to briefly operate unit components for diagnostics Switches (1) Description ALL I2R

Cooling and Heating temperature limits are set independently. Temperature limiting switches in factory set down position except as noted.

Cooling Temperature Limits

Switches Up LC Minimum Temperature Switches Up LC Minimum Temperature NONE 60 6 65 1 64 4,6 70 1,2 66 4,5,6 72 2 68 5,6 74 2,3 70 5 76 1,2,3 72 4,5 78 1,3 74 4 80 3 76 NONE 85

Heating Temperature Limits

13

Central Desk Control

Some installations may want to govern the ability of the unit to operate from a control device remote to the unit or even remote to the room in which the unit is located. The general term given to systems such as this is Central Desk Control. The most common installation of this type of system is a switch mounted at the registration desk and, upon guest check-in, a button is pushed or a switch is moved to allow the air conditioner to operate. Likewise, when the guest checks out, the device is put into the "OFF" position so the unit will not operate while the room is vacant. It is not necessary that the controlling device be located at a central desk to employ a device that will control the unit operation. For instance, in some resort areas, devices are connected to sliding glass doors and opening the door causes a contact to close, turning the air conditioner off. This prevents energy being wasted by operating the air conditioner when warm humid air is entering the room. Some systems operate by motion sensors or heat sensing detectors mounted in the room. These types of systems determine occupant presence in the room and allow the unit to operate; if no one is in the room, the device signals the air conditioner to turn off. Zoneline models offer Load Shedding capabilities on units connected to Central Desk Control Systems. For more information on the Models' Load Shedding Feature, see page 10. All Zoneline 2500, 3500, and 5500 Series units are compatible with simple on/off 2 wire Central Desk Control systems. Consult with the provider of other energy management systems to be sure they are compatible with the GE Zoneline units. Zoneline units have standard connectors factory installed to provide a CDC interface that permits the unit to be connected to most energy management systems. The devices connected to the Zoneline units require no power supply or transformers external to the unit. Important CDC Comments (all series applicable) 1) When the switching device closes the circuit of the CDC conductors, the unit operation stops. 2) Do not use a common buss (at the unit or at the switch panel) in the wiring. Both wires comprising the circuit must connect to the unit connectors and to the controlling switch. Running one wire from one unit to another unit is common bussing and may damage internal components or cause erratic operation of the system. 3) A 24 volt transformer is contained within the Zoneline units. No external voltage may be applied to the unit through the CDC terminals. (Voltage on the CDC conductors is 24 volts AC.) 4) Recommended wire size must be followed as a minimum requirement. Wire Size #AWG #22 #20 #18 #16 Maximum Allowable Length 600 Ft. 900 Ft. 1500 Ft. 2000 Ft. Connecting the Zoneline unit to a CDC system does not eliminate the ability to connect the unit to a remote thermostat. Once the circuit is "opened", and control of the unit removed from the CDC system, the selected controls either the unit mounted control or the remote thermostat govern the operation of the unit. Please see page 57 for installation recommendations for the Central Desk Control wiring.

CDC Terminal Location and Typical Wiring

See page 12 and 13 for location of CDC terminals on unit

Example of Common Bussing NOT PERMITTED

Unit #1

Unit #2

Unit #3

INCORRECT Common Bussing Normally Open Switch Unit Operational

CDC Terminals on Zoneline

Typical Wiring (All Wiring Shown Is Field Supplied)

Freeze SentinelTM remains operational when the unit is connected to a CDC system. Even if the unit is turned "OFF" at the central location, if the sensor at the unit detects the low temperature, the electric resistance heaters and fan will automatically turn on.

14

Remote Thermostat Control

In some installations, control of the operation of the unit at a location remote to the unit itself may be desired. Unit mounting locations (high in the wall or over a transom) resulting in inaccessible unit mounted controls can be connected to a remote thermostat. Other installations may use remote thermostat control for design or (shown closed) performance enhancement. The unit is connected to the thermostat by low voltage wiring, which permits the operation of the unit to be selected and the temperature to be sensed at the thermostat. All Zoneline 2500, 3500 and 5500 Series units are adaptable to Class 2 remote low voltage thermostat. The only additional field supplied components are the remote thermostat and wiring necessary to connect it. The controls on the unit are not functional when the remote control function is used. The Class 2 Mode Switch (dip switch 12 on the auxiliary control board) must be set to the ON/UP mode to enable remote thermostat control. Refer to installation instructions packaged with the chassis. Please see page 57 for installation recommendations for the remote thermostat wiring. Compatibility of other thermostats considered for use with the GE Zoneline unit is the responsibility of the customer. The control voltage on the remote control conductors is 24 VAC. The units may not be compatible with some solid state thermostats. The fan speed for the 2500 series in remote thermostat operation is selected by the connection of the fan wire from the thermostat to either the HIGH or LOW terminal on the unit. See the sketch of the unit terminals for the location of the HIGH and LOW fan speed terminals. Operating in low fan speed reduces the operating sound level of the unit. Freeze SentinelTM remains operational if the unit is connected to a remote thermostat. The unit may be connected to a Central Desk Control (CDC) system and controlled with a remote thermostat when the CDC system has the unit in an operational status. See page 14 for additional information on the CDC system.

Resistance Heat Models

The Zoneline 2500 resistance heat units may be connected to a single-stage thermostat designed for use with cooling with electric heat systems. GE offers 3 thermostats compatible with the 2500 series unit.

GH

GL

B

W

R

Y

RAK163A1 - a mechanical manual changeover thermostat requiring 4 connection wires.

C Common - Ground White - Heater Yellow - Compressor Black - Not Used On 2500 Green - High Speed Fan Green - Low Speed Fan Red - 24 VAC

RAK163D1 - a solid state digital manual changeover thermostat requiring 5 connection wires.

RAK163P1 - a solid state digital programmable auto changeover thermostat requiring 5 connection wires.

15

Remote Thermostat Control

RAK806 Universal Control Cover Label

When a Zoneline unit is using a remote thermostat control, the RAK806 Universal Control Cover Label is recommended. The RAK806 is only available in a package of 10 labels. The label is placed over the control panel directing the user to the wall thermostat for operation of the Zoneline unit. Please see page 57 for installation recommendations for the remote thermostat wiring. Compatibility of other thermostats considered for use with the GE Zoneline unit is the responsibility of the customer. The control voltage on the remote control conductors is 24 VAC. The units voltage may not be compatible with some solid state thermostats. The Class 2 Mode Switch, dip switch #4 on the 3500 & 5500 series must be set to the ON/UP mode to enable remote thermostat control. Refer to installation instructions packaged with the chassis.

Heat Pump Models

The Zoneline 3500 and 5500 Series heat pump units may be connected to a single stage cooling/two stage heating thermostat designed for use with heat pump systems. GE offers 3 thermostats compatible with the 3500 and 5500 series units.

(shown closed)

RAK147 - mechanical manual changeover thermostat requiring 6 connection wires

RAK147D1 - solid state digital manual changeover thermostat requiring 6 connection wires.

RAK147P1 - solid state digital programmable auto changeover thermostat requiring 6 connection wires.

16

Remote Thermostat Control

When connected to a remote thermostat, the indoor air temperature sensing is shifted from the unit to the remote thermostat. For this reason, the units will operate slightly differently when connected to a remote thermostat. The following chart shows the unit operation when connected to a remote thermostat.

Feature Indoor Frost Control Freeze Sentinel Auto Fan Speed Electronic Temperature Limiting Switch to Resistance Heat Based On Indoor Temperature Switch to Resistance Heat Based On Outdoor Temperature Reverse Cycle Defrost Simultaneous Resistance Heat with Heat Pump Resistance Heat Lockout "Smart Fan" Fan Cycle Central Desk Control 3500 Series Yes Yes No No Determined by Remote Thermostat Yes ­ ­ ­ Fan ON/AUTO Set On Remote Thermostat Yes 5500 Series Yes Yes No No Determined by Remote Thermostat Yes Yes No Yes Fan ON/AUTO Set On Remote Thermostat Yes

GH

GL

W

B

R

Y

C Common - Ground White - Heater Yellow - Compressor Black - Not Used On 2500 Green - High Speed Fan Green - Low Speed Fan Red - 24 VAC

Temperature Boost option should not be used with remote thermostat operation since this will cause the unit to switch to resistance heat when outdoor temperatures are below 46°F. See RAK806 Universal Control cover Label on page 15.

Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units

ZONELINE SERIES 2500 THERMOSTAT MODEL RAK163A1 RAK163D1 RAK163P1 RAK147 RAK147D1 RAK147P1 LOW VOLTAGE CONDUCTORS 4 5 5 6 6 6

TYPE Mechanical Digital Digital Programmable Mechanical Digital Digital Programmable

FUNCTION Cooling and Heating

3500 and 5500

Single Stage Cooling 2 - Stage Heating

Thermostat wire size - up to 60 feet AWG20 - up to 66 feet AWG18

17

Remote Thermostat Control

Multiple Units Connected to One Remote Thermostat (2500 Series)

One remote control thermostat may be used to control multiple resistance heat Zoneline units, however the units may not be wired direct. Since each Zoneline unit has an integral transformer, direct wiring can result in a "bucking" or "boosting" voltage condition, and is in violation of the National Electric Code. The diagram below shows the correct wiring for such an installation through the use of field supplied isolation relays.

For Use With Mechanical 4-Wire Systems Only

Remote Control (Low Voltage) Wiring

One stage Thermostat Controlling Three Zoneline Units Resistance Heat Zoneline 2500 Series Units (Not Applicable on Heat Pump Units) FIELD SUPPLIED RELAY SPECIFICATIONS NUMBER OF RELAY DESIGNATION UNITS CONTROLLED R1, R2, and R3 2 POTTER and BRUMFIELD TYPE KA11AY-24 OR EQUIVALENT 3 POTTER and BRUMFIELD TYPE KA14AY-24* OR EQUIVALENT 4 POTTER and BRUMFIELD TYPE KU17A11-24* OR EQUIVALENT MORE THAN 4 USE COMBINATION OF RELAYS SPECIFIED ABOVE NOTE: Current draw through thermostat contacts should not exceed 1.0 amps. *Special order, 100 piece minimum order.

18

Heat Pumps and Energy Savings

· GE Zoneline Heat Pumps are designed to provide cost efficient heat pump operation while monitoring room conditions to maintain comfort. The units employ a logic system monitoring both outdoor and indoor temperatures to determine the heat source, thus increasing energy savings by operating longer in the heat pump mode. Heat pumps save energy and cost less to operate than units with electric resistance heaters as the only heat source. Just as the EER of an air conditioner is an indication of the efficiency of the unit, COP (Coefficient of Performance) is the indication of the efficiency of the heat pump. This relative efficiency of a heat pump compares the unit to electric resistance heat. If a unit has a COP of 3.0, it means the unit will produce three times as much heat at rating conditions for the same electrical input wattage used for electric resistance heat. The compressor is used in heat pump operation just as in air conditioning operation. In heat pump operation, the hot refrigerant gas is directed to the indoor coil rather than to the outdoor coil. Room air that circulates over the indoor coil gains heat from the coil rather than losing heat to the coil as during cooling operation. As the outdoor temperature falls, the heat pump is able to extract less heat from the outdoor air to raise the temperature of the indoor air. For this reason, all packaged terminal heat pumps also have electric resistance heaters as backup to heat pump operation. At some point, the heat pump is unable to provide sufficient heat to adequately warm the room. Many Packaged Terminal Heat Pumps cease heat pump operation and change to more expensive resistance heat at some pre-determined outdoor temperature to compensate for the inability of the heat pump to maintain room temperature. This point, called the "switchover point", is usually at an outdoor temperature where savings from heat pump operation may still be realized, if the unit is designed to maintain room comfort at the lower outdoor temperatures. Balance Point An important consideration of the selection of a heat pump unit is the "balance point" of the installation. Virtually every room is unique - with different insulation - different sizes and types of windows - different types of construction different directional exposures. All of these variables, as well as geographical location, must be considered in order to determine the balance point, the point at which the heat pump is unable to produce enough heat to compensate for the heat loss of the room or area being heated. For these reasons a consulting engineer should be engaged to calculate the heat loss and specify the heat pump unit required. GE offers two series of Zoneline Heat Pump units - the 3500 Series with Standard Microprocessor controls and the 5500 Series with Highly Featured Microprocessor controls - and both series react to the indoor temperature as well as the outdoor temperature in determining the heat source to provide comfortable room conditions and energy savings. This determination of the heat source based on the indoor temperature helps provide a more comfortable room.

· Heat Pump Operation - Zoneline 3500 Series Switchover to resistance heat is determined by indoor temperature differential and outdoor coil temperature The Zoneline 3500 Series heat pumps are Standard Microprocessor controlled units. A solid state thermostat control is used to measure the room temperature and compare it to the temperature selected with the "TEMP" control knob. A temperature sensor is in contact with the outdoor coil to monitor the outdoor coil temperature during heat pump operation. The switchover point of the 3500 Series heat pump is determined by the outdoor coil temperature or the indoor air temperature. When the outdoor coil temperature is above 9°F. (which corresponds to approximately 25°F. outdoor air temperature), the unit attempts to provide sufficient heat through heat pump operation to satisfy the selected temperature setting. The microprocessor monitors the indoor room temperature and determines if the heat pump output is adequate to maintain comfort conditions. As long as the heat pump output maintains the room temperature within 2.7°F of the set point, the unit will operate in the heat pump mode. If the room temperature continues to decline with the heat pump operating, heat pump operation will terminate and the unit will switch over to electric resistance heat to warm the room. This heat source logic allows the heat pump to operate to lower outdoor temperatures, increasing the savings from heat pump operation, while providing the ability to use resistance heat only when necessary. The heat pump and the electric resistance heaters never operate simultaneously on the Zoneline 3500 Series Units. A heat pump override switch is provided in the auxiliary controls to allow the unit to operate only in resistance heat. The use of this option significantly increases the cost for heating. Heat pump defrost - Zoneline 3500 Series If the outdoor coil drops below 9°F. (which corresponds to approximately 25°F. outdoor air temperature), the unit employs a passive defrost system. A "passive defrost system" prevents heat pump operation until outdoor temperatures rise sufficiently to enable economical heat pump operation to resume. During the defrost mode, the indoor temperature is maintained by the electric resistance heater. The defrost cycle terminates when the outdoor coil temperature rises above 36°F., at which point the microprocessor will allow the unit to return to economical heat pump operation. Heat pump condensate See page 34 for information on heat pump condensate. The Zoneline 3500 Series heat pumps may be ordered with a factory installed Internal Condensate Removal (ICR) system to minimize the amount of condensate water draining from the unit during heat pump operation. The ICR system has proven to be an effective means of minimizing the amount of heat pump condensate dripping from the unit. However, if the requirements of a particular installation will allow no dripping of condensate water from the wall case, the installation of an internal or external drain system is recommended. Units with ICR may not be installed in seacoast or corrosive environment applications.

19

Heat Pumps and Energy Savings

· Heat Pump Operation - Zoneline 5500 Series Heat sources: Heat pump, heat pump and simultaneous electric resistance heat, or electric resistance heat The Zoneline 5500 Series heat pumps employ a highly featured microprocessor control system interfaced with thermistors to accurately measure indoor air temperature, outdoor air temperature, indoor coil temperature, and outdoor coil temperature. This system allows the microprocessor to precisely and predictably react to changing conditions in order to provide a very advanced Packaged Terminal Heat Pump operating system. The Zoneline 5500 series is designed to help insure a comfortable room. When "HEAT" is selected, the unit will determine if the room air is warm enough to satisfy the thermostat setting. If the temperature at the unit sensor is below the desired temperature, the electric resistance heater will be utilized to warm the room to the point where the thermostat is satisfied. This feature is designed to allow the temperature of an unoccupied room to be maintained at an energy saving level without inconveniencing the room occupant. Once the thermostat has been satisfied, the resistance heater will turn off and the heat pump will operate as shown in Zoneline 5500 Series Heat Source Logic chart when the thermostat calls for heat again. The unit will operate in this manner even if connected to a Central Desk Control. Zoneline 5500 Series Heat Source Logic

ROOM TEMPERATURE VS. THERMOSTAT SET POINT Less Than 1.8°F. Below 1.8°F to 2.7°F. Below More than 2.7°F. Below Above 46°F. Heat Pump Heat Pump Between 46°F. and 25°F. Below 25°F.

A heat pump override switch is provided in the auxiliary controls to allow the unit to operate only in resistance heat. The use of this option significantly increases the cost for heating.

Heat pump defrost - Zoneline 5500 Series

The Zoneline 5500 Series has a reverse cycle demand defrost system to extend heat pump operation and increase savings from extended operation. The microprocessor determines the need for defrosting by criteria based on continuous compressor running time, outdoor air temperature, outdoor coil temperature, and the rate of temperature change of the outdoor coil. When defrosting is required, the unit reverses the flow of refrigerant to direct the hot gas into the outdoor coil to melt the frost build-up. Before and after the reverse cycle defrosting, the unit shuts off the compressor to allow the refrigerant pressures to equalize throughout the system. This eliminates the possibility of a loud reversing noise. During these periods of pressure equalization, the full resistance heat capacity of the unit is activated to help insure room comfort conditions during the defrost cycle. The unit remains in the defrost cycle for a minimum of 2 minutes up to a maximum of 9 minutes. The defrost cycle terminates when the outdoor coil reaches a temperature of 68°F or the maximum time has been reached. Heat pump condensate See page 34 for information on heat pump condensate. The Zoneline 5500 Series heat pump may be ordered with a factory installed Internal Condensate Removal (ICR) system to minimize the amount of condensate water draining from the unit during heat pump operation.

Heat Pump* Full Resistance Heat Heat Pump + Full Resistance Supplemental Heat Heater Full Resistance Full Resistance Heat Heat

Heat Pump

*If the "Temperature Boost" switch (dip switch #8) is in the "ON" position, the supplemental simultaneous heater will be used with heat pump operation. Simultaneous supplemental heater: 1.0 KW @ 230 V; 0.8 KW @ 208 V; 1.7 KW @ 265 V The "Temperature Boost" option utilizes the supplemental simultaneous heater simultaneously with heat pump operation when the outdoor temperature is below 46°F. regardless of the indoor air temperature. The chart above indicates the heat source of the Zoneline 5500 series heat pump under various indoor and outdoor conditions. The unit is designed to provide heat pump savings without sacrificing room comfort. The Quick Heat Recovery feature is not affected by the Zoneline 5500 Series Heat Source Logic shown in the chart above. For more information about the Quick Heat Recovery Feature, see page 9. The full heat output of the resistance heater is dependent upon circuit amperage and the power connection kit used. See pages 42 - 43 for information on the power connection kits and available heater capacities.

20

Application Comments

Use and Care Manual and installation instructions are shipped with Zoneline units. It is important that any air conditioning system be properly sized and applied in order to achieve the desired temperature and humidity levels with the space to be conditioned. Air conditioners are designed primarily to provide heating and cooling with the additional benefit that during operation in the cooling mode, the units also remove some moisture from the conditioned space. The following are some brief application comments on undersizing, oversizing, heating, wall coverings, and air infiltration: all are important in the proper matching of the heating/air conditioning system to the building structure. Undersizing: If an air conditioner is undersized (cooling capacity is less than required for a specific application), the unit will typically not be able to cool the space down to the desired temperature (thermostat set point), nor be able to remove enough moisture from the air. A result could be a warm and humid or warm and dry conditioned space. Oversizing: If an air conditioner is oversized (cooling capacity is greater than required for the specific application), the unit will typically cool the space down to the desired temperature (thermostat set point) too quickly. The compressor then begins to cycle on and off. Dehumidification only takes place when the compressor is operating. A typical result in a hot/humid climate could be a cool but excessively humid space. Heating: Undersizing can result in not being able to maintain the desired temperature level within the conditioned space. Wall Covering: Use of a non-permeable wall covering (some paints, some wallpapers, and other types of coverings) which severely restricts passage of air or water vapor can cause a severe moisture problem. Typical results could be staining of room surfaces, wall damage, as well as mold and mildew growth in hot/humid climates. Air Infiltration: Excessive air infiltration can magnify problems associated with undersizing or oversizing of an air conditioner unit and can be the root cause of insufficient cooling, dehumidification, or heating. Some sources of air infiltration include vents, gaps around windows and doors, and improperly sealed floor, ceiling and wall joints. Recommendation For the above reasons it is strongly recommended that a professional engineer be retained to match the Zoneline unit with the building structure.

OVER 40 FT.

end, reinstalling the louver section in the room cabinet with the seven screws, and reinstalling the room cabinet on the unit. The unit is shipped from the factory with the discharge louvers at an angle of 50° off vertical. In the alternate position, the louvers will be at an angle of 40° off vertical. All room cabinets return air through the front of the unit. High Wall Mount - For units mounted high in the wall, the discharge louvers should be at a setting that provides the most horizontal air discharge. Recommended installation is at least 3" below the ceiling. In installations where units are close to the ceiling, the most horizontal discharge angle can be obtained by removing the discharge grill from the room cabinet.

50°

Supply Air Throw - One 40° Zoneline unit should not be required to do a job obviously requiring two or more units. Units should be located around large rooms according to calculated loads or in such fashion as to achieve balanced air distribution in all parts of the room. The single unit in the "Incorrect" illustration below obviously cannot condition the entire room. Add a second unit as shown in the "Correct" illustration.

INCORRECT

CORRECT

Air Distribution

Zoneline packaged terminal air conditioners and heat pumps discharge air from the top of the unit through reversible 2-position discharge louvers. Unit discharge louvers are reversed by removing the room cabinet from the unit, removing seven screws that hold the louver section in place, removing the louver section and rotating it end for

OVER 40 FT.

21

Dimensions

42"

A

4" -3/ 13

1/2" SQ. HOLE (2 REQ'D.)

A-Additional Wall Case Depths RAB7116 - 16" RAB7124 - 24" RAB7128 - 28" RAB7131 - 31"

2-3/4"

RAB71 WALL CASE

16"

1-1/2" TYP

1/2"

5-5/8"

4"

WALL OPENING

16-1/4" MIN. x 42-1/4" MIN.

36"

6" 21" 1/2" DIA. HOLE (3 REQ'D.)

42-1/8"

13-7/8"

RAB77 WALL CASE

16-1/4" 1-1/2" 1/2" SQ. HOLE (2 REQ'D.) 9/16"

2-7/8" 5-5/8"

4"

WALL OPENING

16-1/2" MIN. x 42-3/8" MIN.

36"

6" 19" 1/2" DIA. (3 REQ'D.)

RAB71 = 42" RAB77 = 42-1/8"

GRILLE

RAB71 = 20-7/8" RAB77 = 21"

7-1/8"

GRILLE

WALL CASE WITH CHASSIS INSTALLED

RAB71 = 13-3/4" RAB77 = 13-7/8"

TOP VIEW SIDE VIEW INSIDE RAB71 = 16" RAB77 = 16-1/4" OUTSIDE

42"

ROOM CABINET

ROOM CABINET

FRONT VIEW*

SIDE VIEW 2-3/8" MIN.

INTERIOR WALL

WALL CASE WITH SUB-BASE

12-3/4" 12"

KNOCKOUTS (ENCLOSURE) 4 REAR; 4 BOTTOM

13" 1-7/16" 3-1/2" 9-3/8" 2-1/2" LEVELING SCREW

1-5/16"

3" MIN. ADJUSTABLE TO 5" MAX.

SEE PAGE 32 FOR KNOCKOUT LOCATION DIMENSIONS.

FINISHED FLOOR

*SHOWN WITH ACCESS COVERS REMOVED. NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

Installation Instructions Packed With Wall Case . . . See Page 25 For Additonal Information Concerning Outdoor Weather Panel and Case Stiffener.

22

Wall Case

A choice of wall cases is available for the Zoneline unit. RAB71 - This insulated case is constructed of heavy gauge galvanized steel and finished with a protective baked enamel finish for protection and appearance. Design of the case provides for RAB71 Wall Case support of the chassis and free draining of any water entering the wall case. A petroleum microcrystalline wax is applied at critical points of fabrication to seal against moisture. The dimensions of the RAB71 wall case are: 42" wide by 16" high by 13 3/4" deep, the same dimensions as the original wall case for GE Zoneline units built in 1961. The RAB71 wall case is also available in depths other than the standard depth of 13 3/4". Special order steel case are: RAB7116 - 16" deep; RAB7124 24" deep; RAB7128 - 28" deep; and RAB7131 - 31" deep. All of these special order deep wall cases are insulated and have sheet metal dividers, or splitters, to prevent the recirculation of condenser discharge air. RAB77 - This noninsulated wall case is molded from fiberglassreinforced polyester compound. This SMC (Sheet Molded Compound) wall case RAB77 Wall Case offers outstanding strength, durability, color retention, water integrity and corrosion resistance. The dimensions of the RAB77 wall case are: 42 1/8" wide by 16 1/4" high by 13 7/8" deep. · Both wall cases are of universal design, accepting all Zoneline chassis of current design as well as all GE Zoneline chassis produced since 1961. · Drain holes are provided in the rear of the wall case to permit excessive cooling condensate water, heat pump condensate, or precipitation entering the wall case to drain freely. A drain kit may be connected to the wall case to control any water draining from the wall case. See pages 34 - 36 for information on RAD10 Drain Kit. RAK901L - For installations when the wall case extends into room, an RAK901L is an insulation kit that can be used with the RAB77 or any existing non-insulated wall case to minimize the possibility of condensation forming on the indoor side of the case during the winter. "Permanent Connection" generally means wiring between the building wiring and the unit must be contained in an enclosed "chaseway", where access to the wiring connections is more restrictive than a normal line cord plugged into a receptacle. NEC requirements may be met by using flexible or rigid conduit to contain the wiring between the unit and a junction box that contains the wiring connections. The conduit is connected to the unit and to the junction box with connectors to hold the conduit in place. The junction box may be located in the floor or the wall of the structure but only approved connectors may be used outside the unit or the junction box. The sub-base is UL® listed as a junction box for permanent connection of a Zoneline unit. Using a sub-base in an installation requiring permanent connection provides a convenient, consistent location for unit wiring to be connected to building wiring. The use of a sub-base is not required, but the convenience and the improved aesthetics it offers makes the use of a sub-base a viable means of permanent connection.

Chaseway RAK204 - The RAK204 Series of sub-bases provides a variety of designs that fit the site needs Typical RAK204D20 sub-base shown and are available for use with Zoneline PTAC/PTHP units. The RAK204U will most likely be used for support of the wall case and unit.

208/230 volt receptacles can also be mounted in the cover plate for easy access when direct connect wiring is not required. 265 volt units are to be "Direct Connected" and the external receptacle (when wiring is not enclosed in a chaseway) does not meet this requirement. A knockout for a fuseholder or a disconnect is also provided in the cover plate. RAK204U - No receptacle or wiring but will accept any field supplied 15, 20 or 30 amp receptacle and wiring. Chaseway not included. RAK205CW chaseway must be ordered separately. The RAK4002A (2500/3500 Series) or RAK4002B (5500 Series) junction box performs the same function as any of the other sub-base kits by selecting the correct receptacle and installing it in the interior mounting plate inside the RAK204U. RAK204D20 ­ 208/230 volt 15/20 amp receptacle. Receptacle is NEMA6-20R (GE4181-2 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included. RAK204D30 ­ 208/230 volt 30 amp receptacle. Receptacle is NEMA6-30R (large tandem) with 18" of #12AWG wires attached to the receptacle. Chaseway included. RAK204E15 ­ 265 volt 15 amp receptacle. Receptacle is NEMA7-15R (GE0716-6 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included. RAK204E20 ­ 265 volt 20 amp receptacle. Receptacle is NEMA7-20R (GE0720-3 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included. RAK204E30 ­ 265 volt 30 amp receptacle. Receptacle is NEMA7-30R (GE0730 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included.

Sub-Base

The sub-base is an optional accessory for the Zoneline unit and is presented with the wall case information since the decision to use or not to use a sub-base in the installation is a factor in the location of the wall opening for the unit. National Electrical Code® requires that air conditioning units connected to voltages in excess of 250 volts be "permanently connected". There are also some installations where units connected to voltage sources under 250 volts may also need to be "permanently connected". If you are in doubt about the requirements for a particular installation being designed, consult Article 440 of the NEC or the local electrical inspector. These requirements are designed to protect personal safety and should be strictly followed. Although NEC is cited here as a reference, all electrical wiring and installations must conform to any and all local electrical codes and regulations.

23

Sub-Base (Cont.)

There are separate internal compartments to permit separation of low voltage (Class 2) connections from line voltage connections as required by NEC. Conduit containing building wiring enters the sub-base through knockouts located in the rear or bottom of the sub-base and is not accessible when the wall case is installed. The sub-base attaches to the RAB71 wall case with two clips (field assembled) that are screwed into pre-drilled holes in the bottom front flange of the wall case. It attaches to the RAB77 wall case with clips that fit over molded ribs without requiring the use of screws into the wall case. See page 33 for illustration. Since the sub-base extends under the wall case, clearance from the inner edge of the wall case to the finished wall must be 2-3/8" or greater. The sub-base has 4 leveling legs and adjustable side channels to enable the area under the wall case to be enclosed. Clearance from the bottom edge of the wall case to the finished floor must be between 3" and 5". The sub-base may be used as support for the chassis and wall case in installations where the wall is of insufficient thickness to provide secure mounting of the wall case.

any water entering the wall case, either from operation of the unit or from other sources, such as rain storms or from washing the exterior of the building, will drain from the case without the possibility of capillary action drawing the water into either the room or the wall cavity. In an installation where the case is recessed less than 3" from the outside surface, flashing and sealing may be all the modificaton necessary. In such an installation, the sides and top of the wall opening must be waterproof to prevent moisture from seeping into and damaging the walls. See Pages 30 and 31 for suggested detail. Since the installation of a case extension requires a considerable amount of attention, we recommend using one of the deep wall cases if the standard case is not of sufficient depth. Mounting an outdoor grille or louver section to the building face may cause a space between the outdoor coil and the louver section. Air splitters, aligned with the ends of the outdoor coil, must be installed between the outdoor coil inlet and outlet air streams. Gaps between the outdoor coil and the louver section may allow condenser air recirculation and affect the operation of the unit. See page 40 for requirements for custom louver sections. The wall case should be level from side to side and from level to 1/4 bubble tilt to the outdoors. The condensate disposal system in the unit is designed to dissipate the condensate water generated during cooling operation in accordance with ARI standards and actually uses this water for maximum unit efficiency. A level unit will also insure proper performance of the Internal Condensate Removal (ICR) system optional on heat pump units. For new construction, early planning with the architect is necessary. Unit location, electrical connection locations, and wall openings of the proper dimensions are essential to avoid the necessity of rework, fillers, framing, moving electrical outlets, and other expensive modifications. For existing construction it is important that carpentry, masonry and electrical work be performed by competent, qualified personnel. Since installations in existing construction may involve removal of building material from the structure, locating the wall case must be done correctly.

Wall Case Installation Data

General Generally, Zoneline units are installed 3" to 5" above the floor (flush to finished floor installation is possible) as near to the center of the room as possible; underneath a window or a glass panel is typical. Normal installation of the wall case allows installation flexibility; from flush with the finished interior wall to a minimum of 1/4" of the wall case extending beyond the finished exterior of the building. Special consideration must be given to installations where the wall case does not extend a minimum of 1/4" beyond the finished exterior wall. See pages 30 and 31 for information on this type of installation. The unit may be installed high in the wall and these installations usually require a remote thermostat and are discussed on pages 17 and 18. Regardless of the installation, there are several things to consider when selecting a location for installing the unit. For instance, drapery location could interfere with air discharge, and placement of furniture may have an impact on the performance of the unit. The following information is intended to minimize installation problems and assure you of trouble-free installation. Refer to page 22 for required wall opening dimensions. Minimum recommended interior and exterior case projection for standard wall thicknesses are shown in the drawings in this manual. The case may be installed flush with the finished indoor wall. Special attention must be paid to room-side case projection when the unit is installed in a ducted application as shown on page 39. In walls thicker than 13 1/2" for line cord connected units and 11 1/8" for sub-base installations, it may be necessary to install a field fabricated case extension or use one of the special order RAB71 deep wall cases. If you are unable to locate a local source for case extensions please contact your salesperson for a possible supplier. Such extension must be carefully flashed and sealed both to the wall case and to the wall to insure water integrity. This is necessary to insure that

Window, Curtain and Panel Wall Construction

With this type of construction, provision for support of the unit, other than by the wall itself, is often required. Such support may be in the form of wood or metallic material of the proper thickness to maintain a level case. This additional support should be located both near the wall and at the front of the wall case. Sub-base (RAK204 Series) with four leveling legs provides an excellent support for the unit in this type of installation. See page 28 for details of this type of installation. In existing construction, common practice is to remove a pane of glass, metal, wood, or other construction material and build a frame around the wall case. Similar filler panel material may be installed around the case for appearance and weather seal.

24

Masonry Wall Construction (Cont.)

The wall case should be installed during construction and lintels should be used to support the blocks above the wall case. The wall case will not support the concrete block. The installation instructions show how the wall case must be secured to the masonry and caulked. Do not remove the cardboard stiffener supplied with the wall case until ready to install the chassis. See page 29 for details of installation in masonry wall. For existing masonry construction, wall openings must be made by removing concrete blocks to achieve the proper size opening. Consult the builder, architect, or owner to determine the necessity for lintels to support the block above the wall case. Anchor bolts are normally required to secure the case to the wall and shims may be required to prevent distortion of the wall case when securing the wall case to the wall. Field supplied case angles can be used to position and secure the wall case to the wall and to cover oversized wall openings.

The wall case should be level from side to side and from level to 1/4 bubble tilt to the outdoors. The condensate disposal system in the unit is designed to dissipate the condensate water generated during cooling operation in accordance with ARI standards and actually uses this water for maximum unit efficiency. A level unit will also insure proper performance of the Internal Condensate Removal (ICR) system optional on heat pump units. 2. The wall case should be secured to the wall at both sides. Use a minimum of two screws or other fastening device on each side. See Figure 2 page 26. Mark the wall case on each side 2" from the bottom and 2" from the top at a point where basic wall structure is located. Drill wall case and use fasteners appropriate for wall construction. All holes for fasteners in the side of the wall case must be at least 2" up from the bottom of the wall case. Never locate screws or put other holes in the bottom of the wall case. The only exception is when an RAD10 drain kit is installed to connect to an internal drain system. See page 36 for RAD10 Drain Kit information. If the wall opening is greater than the case dimensions, spacers must be used on the sides between the wall case and the wall support structure to prevent distorting the wall case. 3. Caulk or gasket the entire opening on the outside between the wall case and exterior wall surface (4 sides) to provide total water and air seal. 4. Caulk or gasket room-side opening between wall case and interior wall surface (4 sides). Opening beneath or around the wall case can allow outdoor air to leak into the room resulting in increased operating costs and improper room temperature control. Care should be taken in location of electrical supply entry in relationship to wall sleeve to assure access to receptacle or junction box once unit is installed. · Refer to page 42 for maximum power cord length. · Permanent connected units close to finished floor must allow for conduit clearance.

Brick, Frame, Stucco and Shingle Construction

For new construction, the opening for the wall case should be framed and the wall case inserted into the opening during construction. Lintels should be used when the building material is heavy and is not self supporting (such as brick). The wall case will fit an opening of six courses of standard brick or five courses of jumbo brick. Wall framing in this type construction is normally on 16" centers and the wall case will fit a framed opening spanning three 16" O.C. 2" x 4" stud spaces. For existing construction the indoor and outdoor wall will need to be cut out, allowing for clearances of 1/8" on all sides of the wall case. Work should begin on the inside wall. Cut the correct dimensions and mark (using drill holes) the outside wall from each corner of the inside cutout. Studding that interferes with the opening must be removed and a suitable frame constructed to secure the wall case and provide adequate support for case and chassis.

Case Angles

In some installations such as curtain walls, window walls, or where the structural material of the wall is insufficient to support or fasten wall case to, the use of case angles may be used. Case angles are pieces of steel or other material of similar structural strength that are formed to a 90° angle, with holes to fasten the case angle to the wall case and to the structural component of the wall surrounding the wall case. The following describes the procedure when field fabricated and installed case angles are applied. 1. Position case angles around top and sides of wall case at the desired location. Position case angles vertically on each side of wall case to provide a level installation. 2. Mark wall case through holes in case angles. The lowest hole on the sides of the wall case must be a minimum of 2" above the bottom of the case. 3. For RAB71 wall case drill 5/32" diameter holes at locations marked on wall case in Step 2, and assemble angles to wall case using #10 x 1/2" self tapping screws. For RAB77 wall case follow the same procedure except use a #10 x 1/2" bolt, washer and nut to attach case angles to case. Install screws or bolts from outside wall case. 4. Do not drill any holes in bottom of wall case. Do not distort wall case. 5. Do not use case angles for a lintel.

Preparation of the Wall Case for All Types of Construction

As shipped, the RAB71 or RAB77 is ready for installation. Do not remove the stiffener from inside the wall case or the weather closure panel from the outside face of the wall case until the outdoor grille and chassis are ready to be installed.

Installation of Wall Case in Wall Opening

1. Position the wall case into the wall. The room side edge of the RAB71 or RAB77 wall case should be at least flush with the finished wall for line cord installations and permanent connection installations when no sub-base is used, and should project into the room at least 2-3/8" when a subbase is used. If the minimum exterior dimensions are not met, refer to page 27 and 28. The outside edge of the wall case should extend at least 1/4" beyond the outside wall. This is necessary for proper caulking, to prevent sealing the drain holes in the rear flange of the wall case, and to facilitate the installation of an accessory drain, if used.

25

26

FASTENING WALL CASE

MAIN STUDS HEADER JACK STUD HEADER ­ 4" x 4" OR 2 - 2" x 4" ON EDGE LINTEL MOUNTING SCREW HOLE

Framing detail for this construction is as shown in Figure 1. Note use of lintel under first course of brick above the Zoneline case. Do not use the case as a lintel. Mounting screw holes shown are to be made by the installer.

FRAMING FOR WALL CASE

BRICK VENEER AND FRAME CONSTRUCTION

MAIN STUD

JACK STUDS

16-1/4" MIN. RAB71 16-1/2" MIN. RAB77 ADJUSTABLE FRAMING TO SECURE THIS DIMENSION 42-1/4" MIN. (RAB71) 42-3/8" MIN. (RAB77)

NO HOLES PERMITTED IN BOTTOM OF CASE (EXCEPTION -RAD10 DRAIN KIT)

JACK STUD FINISHED FLOOR SUB-FLOOR

CRIPPLE WOOD SCREW MOLLY OR TOGGLE BOLT NO HOLES PERMITTED IN BOTTOM OF CASE

2" MIN.

EXPANSION ANCHOR BOLT

Note: Do not remove the stiffener support from inside the wall case until the chassis is to be installled.

(EXCEPTION - RAD10 DRAIN KIT) JACK STUD MAIN STUD

Choice of attachment devices through both ends of case or the top. Mounting screw holes and attachment devices by installer.

Figure 1

Figure 2

WALL SECTION ­ DETAILED SIDE VIEW

FRAME AND BRICK VENEER INSTALLATION

Cord Set Connected

Sub-Base Connected

LINTEL 2-3/8" STEEL LINTEL CAULK* CAULK* 1/4" CAULK*

CAULK*

RAB71 13-3/4" RAB77 13-7/8" 20-7/8" (RAB71) 21" (RAB77)

RAB71 13-3/4" RAB77 13-7/8" 20-7/8" (RAB71) 21" (RAB77)

MOUNTING SCREWS BY INSTALLER RAB71 16" RAB77 16-1/4" OUTDOOR GRILLE ROOM CABINET WALL CASE 2" MIN.

MOUNTING SCREWS BY INSTALLER RAB71 16" RAB77 16-1/4" WALL CASE SIDE CHANNEL

CAULK*

OUTDOOR GRILLE

ROOM CABINET

2" MIN.

1-5/16" 3" MIN. 5" MAX. 3-11/16"

CAULK*

1/4" MIN. RAG60 1/4" RAG61, 62, 63 1-3/8" RAG64, 65, 66 1-3/8" POWER SUPPLY CONDUIT

FINISHED FLOOR OR TOP OF CARPET

SUB-BASE (RAK204) CAULK* POWER SUPPLY CONDUIT (ALTERNATE ENTRY)

*Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.

FINISHED FLOOR OR TOP OF CARPET

WALL RECEPTACLE (BY OTHERS)

*Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.

27

28

WALL SECTION ­ DETAILED SIDE VIEW Sub-Base Connected

WALL OR WINDOW CASE ANGLE (FIELD SUPPLIED) Gasket and caulk around perimeter of wall case all four sides where it joins the building RAB71 22-1/4" RAB77 22-3/8" WITH RAG61-66 RAB71 21-1/8" RAB77 21-1/4" WITH RAG60 RAB71 RAB71 16" RAB77 16-1/4" OUTDOOR GRILLE WALL CASE 16-1/4" ROOM CABINET ROOM CABINET 16" 16" RAB77A 16" RECEPTACLE (BY OTHERS) SIDE CHANNEL GASKET (FIELD SUPPLIED) (RAK204) SUB-BASE LEVELING LEG 3" MIN. 5" MAX. FLOOR FLOOR POWER SUPPLY CONDUIT (ALTERNATE ENTRY)

WINDOW, 2" CURTAIN OR PANEL WALL INSTALLATION WITH RAG REAR GRILLE EXTENDED BEYOND OUTER WALL SURFACE

Cord Set Connected

Gasket and caulk around perimeter of wall case all four sides where it joins the building

CASE ANGLE (FIELD SUPPLIED)

RAB71 22-1/4" RAB77 22-3/8" WITH RAG61-66

RAB71 21-1/8" RAB77 21-1/4" WITH RAG60

OUTDOOR GRILLE

WALL CASE

USE NO SCREWS IN BOTTOM OF CASE

MIN. 2 SUPPORTS FIELD SUPPLIED

WALL CASE INSTALLATION ­ CORD SET CONNECTED

EXAMPLE: BLOCK AND VENEER ­ DIMENSIONAL DATA AND COMMENTS ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

CASE RAB71 42" RAB77 42-1/8" CAULK* A Dimension A B C RAB71 13-3/4" RAB77 13-7/8" CAULK* E C D

Manufacturer Required Minimum Installation Clearance 1/4" (See note 1) Allow For Electrical Wiring 0" Min. (See page 27) 0" Minimum 0" Minimum 2" Recommended See pages 38-39 for ducted application. 3" Minimum

CAULK*

FINISHED EXTERIOR WALL

CAULK*

NOTE: 1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 35 FOR DRAIN INSTALLATION.

D D

ROOM CABINET

FINISHED EXTERIOR WALL 27-1/4"

MAX. WALL THICKNESS 13-1/8" ADJACENT WALL

2-1/2"

TOP VIEW

ADJACENT WALL

*Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior. LINTEL

SIDE VIEW OF ALTERNATE HIGH MOUNT With conduit power supply. E

CAULK* A CAULK*

ROOM CABINET

WALL OPENING 16-1/4" x 42-1/4" MIN. FOR RAB71 16-1/2" x 42-3/8" MIN. FOR RAB77

INSIDE ROOM CABINET 7-1/8" RAB71 13-3/4" RAB77 13-7/8"

16" RAB71 16-1/8" RAB77

CAULK*

B FRONT VIEW

ELECTRICAL RECEPTACLE (BY OTHERS). FLUSH MOUNTED.

CONDUIT FIELD SUPPLIED FINISH FLOOR

*Caulk around perimeter of wall case all four sides whiere it joins the building Interior and Exterior.

See page 42 for line cord length.

29

30

METAL CASE EXTENSION FOR WALLS DEEPER THAN 13-1/8" (11-1/8" WITH SUB-BASE)

5. Suggested materials for case extension and flashing should be non-ferrous metals. Minimal acceptable material: Galvanized G-90 painted.

CAULK*

WALL ANY CONSTRUCTION

FIELD FABRICATED ­ GE RECOMMENDS THE USE OF ONE OF THE DEEPER RAB71 WALL CASES OFFERED AS SPECIAL ORDER ITEMS. SEE PAGE 29.

1/4" MIN. CAULK*

2. The wall case and extension should be connected prior to installation in the wall opening. A quality grade sealant should be applied to all four (4) butting flanges. Use bolts and nuts or oversized self tapping screws (driven from the wall case to the extension) to attach the two assemblies. Clean all drain holes of excess sealant. The assembly must be free draining. 3. Install flashing, using a quality grade sealant between the flashing and wall as shown in section A-A below. 4. Install the wall case/extension assembly following procedures described for a standard installation. See diagrams below. The assembly should be sealed or caulked to the wall around all four sides both outdoors and indoors. NOTE: The wall case/extension assembly should be level.

ROOM CABINET RAB71/77 CASE EXT. 6-1/4" ± 1/4" AS REQ'D. SEALANT - ALL FOUR (4) FLANGES D

Zoneline units can be installed in walls of greater depth than the wall case. Where the case recession is less than 3" and where it is possible to waterproof the exposed sides and top of the opening, the suggested procedure is to apply a flashing to the bottom of the wall case as shown on page 29. Where waterproofing is questionable or not possible, or for installations in walls of greater depth, the following is a suggested application procedure. It involves the field fabrication of a case extension. Since the wall case is a water bearing container, the extension likewise must also be water bearing and the connection between the two must be watertight. The case extension must contain splitters to prevent recirculation of the outdoor air circuit. 1. The case extension is field fabricated. The extension depth "D" should allow for a minimum outdoor projection of 1/4". This allows for room cabinet clearance to the finished wall and ample surfaces to apply sealant or caulking for a tight weather seal between the completed wall case/extension assembly and the wall opening. It is recommended that the extension be painted and corner and lap joints be additionally sealed with a quality grade sealant.

CAULK*

CAULK*

SPLITTER BETWEEN AIR INTAKE AND DISCHARGE

/4" ±1

SEE DETAIL SECTION A-A

*Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.

8" -5/ 10

SECTION A-A BASEPAN/FLANGE DESIGN SHOWING SEALANT LOCATIONS. ALL 4 FLANGES EXTENSION WALL CASE ALL 4 SIDES

RAB71/77 WALL CASE

EXTENSION (FIELD SUPPLIED)

1-1/2" (4 SIDES)

CUT DRAIN SLOTS IN BOTH FLANGES (FOUR REQUIRED) TO MATCH DRAIN HOLES IN RAB71/77

FLASHING

ALL 4 SIDES

FLASHING (FIELD SUPPLIED) 1" WIDE 45° DRIP LIP

FLANGES AND DRAIN HOLE LOCATIONS SAME AS ON WALL CASE

WALL

2" MIN.

13-3/4" + D"

ALTERNATE ­ CASE RECESSION LESS THAN 3" WITH SIDES AND TOP OF WALL OPENING WATERPROOF, FLASHING ON BOTTOM ONLY

A

B D

For an installation that will provide better protection against water infiltration, GE recommends the use of one of the deeper RAB71 wall cases offered as special order items. See page 23. B

C

OUTDOOR GRILLE

CASE CAULK*

FLASHING

A

DRIP

DIMENSIONS: *Caulk around perimeter of wall case all four sides A. DISTANCE FROM GRILLE OR CASE TO OUTSIDE SURFACE OF WALL PLUS 2" TO 4" where it joins the building - Interior and Exterior. (TO INSERT UNDER CASE). B. 1" DRIP LIP (MINIMUM) C. 42" PLUS - SUFFICIENT TO FIT SNUGGLY UNDER AND UP AROUND THE CASE. D. 2" MINIMUM (CAUTION: WHEN CAULKING DO NOT BLOCK DRAIN HOLES IN CASE OR GRILLE.) IF GRILLE IS TO BE MOUNTED TO WALL SURFACE A SPLITTERS MUST BE USED, SEE PAGE 30.

31

ROOM CABINET

32

RAB71/77 WALL CASE INSTALLATION - RAK204 SERIES SUB-BASE CONNECTED

EXAMPLE: FRAME & BRICK VENEER - DIMENSIONAL DATA AND COMMENTS ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

Manufacturer Required Minimum Installation Clearance 1/4" (See note 1) 3" Min. (5" MAX.) 2-3/8" Minimum 0" Minimum 2" Recommended See pages 38-39 for ducted application. Dimension A B TOP VIEW RAB71 13-3/4" RAB77 13-7/8" D LEVELING SCREW C

NOTE: 1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 31 FOR DRAIN INSTALLATION. 7.70" 18.86" 1.5" 8.80"

2-3/8" MIN.

LEVELING SCREW

FINISHED INTERIOR WALL

5.15"

BACK VIEW SIDE VIEW WITH WALL CASE SHOWN IN PLACE 1-5/16"

10.30"

5.15"

7.70"

2-3/8" INTERIOR WALL

RAB71 16" RAB77 16-1/4"

MAX. WALL THICKNESS 11-1/8"

RECOMMEND 2" TO INTERIOR ADJACENT WALL BOTH SIDES. 1-1/2" 7/8" 42" SEE NOTE LEFT SIDE FRONT VIEW D

3" MIN. ADJUSTABLE TO 5" FINISHED FLOOR MOUNTING SCREWS AND HOLES BY INSTALLER

CAULK* C A

*Caulk around perimeter of wall case all four sides where it joins the building Interior and Exterior.

D

13-3/4"

RAB71 16" RAB77 16-1/4" 3-11/16"

2-3/8" MIN. CASE EDGE TO FINISHED WALL

INTERIOR ADJACENT WALL 12-7/8" 13"

12-3/4"

B FINISHED FLOOR LEVELING SCREW KNOCKOUT SIZE LARGE 1-1/8" DIA. SMALL 7/8" DIA. KNOCKOUTS (ENCLOSURE) 4 REAR; 4 BOTTOM

CAULK* CAULK* LEVELING SCREWS (2) SUB-BASE BODY (2) SIDE EXTENSIONS CONDUIT ENTRY (ALTERNATES) SIDE VIEW

*SHOWN WITH ACCESS COVERS REMOVED. NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

RAK204 SERIES SUB-BASE INSTALLATION AND ELECTRICAL DATA

RAB71/77 WALL CASE

CHASEWAY OPTION (Shown Without Chassis and Wall Case for Installation Location Only.) RAK4002B NOTE: TYPE "E" MOUNTING CLIP MUST BE USED WITH MOLDED CASE. GREEN GROUND SCREW (TYPE "C") METAL CASE 6"

MOLDED CASE

6"

5/32" DIA. HOLE (SEE NOTE) FOR SECURING TYPE "D" CLIPS TO SLEEVE USING TYPE "A" SCREWS

TYPE "B" SCREW SCREW CLIP TYPE "D" TYPE "A" SCREW

SUB-BASE MOUNTING CLIP TYPE "E"

TO SECURE SIDE CHANNELS

TYPE "A"

TYPE "B"

TYPE "C"

TYPE "D"

USE WITH RAB71

TYPE "A" SCREW TYPE "E" 6 REQ'D. 2 REQ'D. 8 REQ'D. TYPE "C" SCREW ACCESS PLATES NOTE: IF METAL CASE DOES NOT HAVE SCREW HOLES, 5/32" DIA. HOLES MUST BE DRILLED 6" FROM EACH SIDE IN FRONT FLANGE. (SEE INSERT). USE WITH RAB77

TYPE "C" SCREW SIDE CHANNELS ARE ADJUSTABLE FROM 13-3/4" TO 2-3/8" IN LENGTH BY BREAKING OFF SECTIONS OF SIDE CHANNELS.

Electrical wiring may enter the sub-base through any of the knockout holes provided in the sub-base. Knockout holes in the sub-base access plate may accommodate a receptacle, which allows the use of a power cord (if permitted by code for the particular installation). A knockout for a circuit breaker, fuseholder or a disconnect is also provided. See page 23 for description of electrical contents of these sub-bases.

33

Condensate Disposal Systems

Cooling Condensate Air conditioners produce condensate water as a result of lowering the humidity of the area being conditioned. When the indoor coil temperature is below the dew point, moisture in the air condenses into water droplets on the coil. This water drains to a pan located under the indoor coil and is routed through the barrier, the partition separating the indoor and outdoor sides of the unit, to the base pan on the outdoor side. It is then picked up and dispersed against the outdoor coil, which is hot when the unit is in the air conditioning mode. The water is evaporated into the atmosphere by contact with the hot outdoor coil. This evaporation process also helps lower the temperature of the outdoor coil and improves the operating efficiency of the unit. Slinger Ring Systems Packaged Terminal units employ various means of dispersing the condensate water against the outdoor coil. One of the most popular, and most effective, means is by the use of a "slinger ring". A "slinger ring" is a ring around the circumference of the outdoor fan. The design of the unit positions the slinger ring very close to the bottom of the base pan so water in the base pan is lifted by the rotating ring. Water picked up by the slinger ring will be dispersed into the air stream and deposited on the hot outdoor coil where it evaporates. All Zoneline Series Packaged Terminal Air Conditioners and Packaged Terminal Heat Pumps utilize a slinger ring for cooling condensate disposal. Certification Test Requirements ARI (Air Conditioning & Refrigerating Institute) requires that all certified Packaged Terminal Air Conditioners and Packaged Terminal Heat Pumps pass a cooling condensate disposal test. One stipulation of the ARI test is that "the test start with condensate collection pan brimful". In order to pass the ARI Condensate Disposal Test the unit must operate continuously for four hours without condensed water blowing, dripping, or running off the unit casing during the test or after the unit has been turned off. Under extremely high outdoor humidity conditions or extreme operating conditions, such as exceptionally high air infiltration (a door or window left open while the unit is running, for instance) it is possible for any air conditioner to be unable to dissipate all the cooling condensate generated. All Zoneline Series Packaged Terminal Air Conditioners and Packaged Terminal Heat Pumps meet the condensate disposal requirements of ARI standards 310-93 and 380-93. Heat Pump Condensate During the operation of a unit in the heat pump, or "reverse cycle", mode the outdoor coil becomes the cold coil and the indoor coil becomes the hot coil due to reversing the flow of the refrigerant. When the temperature of the outdoor coil is below the dew point, condensation will form on the outdoor coil just as it does on the indoor coil during cooling operation. Since the dew point is humidity as well as temperature related, there may be more condensate on days when the relative humidity is high. Heat Pump Condensate Disposal Since the outdoor coil is cold during heat pump operation, the condensate water cannot be deposited on the outdoor coil as the water would cause frost to form on the coil. This frost would block the air flow through the coil and greatly diminish the ability of the heat pump to extract heat from the outdoor air. Rather than allow this problem to occur, heat pump units must dispose of the condensate in another manner. Temperature Activated Drain Valve The most widely used method of disposing of heat pump condensate is with a "Temperature Activated Drain Valve". This is a device mounted in the base pan of a heat pump unit with a bellows that expands on temperature rise and contracts with temperature drop. A shaft with a rubber plug on the end is connected to the bellows. When the outdoor temperature remains above a certain temperature, the bellows is expanded and the plug fits tightly into a hole in the bottom, or base pan, of the unit. When the plug is blocking the hole, as it should be during cooling operation, the condensate water is contained in the base pan. At temperatures when heating is required, the bellows contracts, the rubber plug is retracted from the hole and the heat pump condensate water is allowed to drain into the wall case. The valve is fully open at 49°F. Drain Kits Although the Zoneline units are designed to dissipate all of the condensate generated during normal cooling operation, there may be times when abnormal operating conditions cause more condensate than the unit can dissipate. Heat pumps also generate condensate that the unit may not be designed to dissipate. For these reasons, if condensate dripping from the wall case is objectionable, an internal or external drain system should be installed. See pages 35 and 36 for information covering the drain systems and the RAD10 kit available to connect to the wall case. Internal Condensate Removal (ICR) System GE has developed an Internal Condensate Removal (ICR) System for Packaged Terminal Heat Pumps. This system has been offered as an option on Zoneline Packaged Terminal Heat Pumps since 1982, and thousands of them are in use. During heat pump operation the ICR system utilizes a small pump to lift the water from the base pan and pump it into a collector tray positioned above the indoor coil. The water drains from the collector tray and drips onto the warm indoor coil where it is evaporated into the room atmosphere. If an excess amount of water is pumped to the indoor side, it is routed back to the outdoor portion of the base pan. The ICR system has proven to be an effective means of minimizing the amount of heat pump condensate dripping from the unit. However, if the restrictions of a particular installation will allow absolutely no drippage of condensate water from the wall case, the installation of an internal or external drain system is recommended. Units with ICR may not be installed in seacoast or corrosive environment applications.

34

WALL CASE WITH RAD10 DRAIN KIT

EXTERNAL DRAIN SEE PAGE 36 FOR INTERNAL DRAIN

SCREWS

"A"

"B"

METAL

PLASTIC

SEE PAGE 36 NOTE #6

SQUARE DRAIN HOLES 1/2" O.D. 90° ELBOW DRAIN TUBE NEOPRENE SPONGE GASKET

NOTE: SHADED PARTS AND SCREWS ARE INCLUDED WITH RAD10 DRAIN KIT. USE EITHER THE 90° Alternate ELBOW TUBE OR THE 6" long, 1/2" STRAIGHT TUBE O.D. straight DEPENDING UPON THE copper tube. REQUIREMENTS OF THE PARTICULAR INSTALLATION.

TYPICAL INSTALLATION CASE ANGLES (FIELD SUPPLIED) Caulk around perimeter of wall case all four sides where it joins the building.

STEEL MOUNTING PLATE

USE TYPE "A" SCREW FOR METAL CASE (RAB71) AND TYPE "B" SCREW FOR MOLDED CASE (RAB77)

WATER DRAINAGE - Precipitation entering the unit through the outdoor louver may not be removed entirely by the condensate removal system. The base pan flange is designed to allow excess water, either condensate water or precipitation, to flow into the wall case and drain through two drain holes in the rear of the wall case. If there is more water in the wall case than can be drained through these holes it will drain through the three overflow drain holes. These drain holes must not be blocked when mounting or caulking the wall case.

REAR GRILLE 90° ELBOW DRAIN TUBE PROJECTION BEYOND WALL CASE 3" 4"

WALL CASE

ROOM CABINET

For those installations where water draining from the drain holes is objectionable or where positive drainage is desired, the RAD10 drain kit is available with either a 90° elbow or a 6" straight tube to be used either to connect to a field supplied drain line or to allow the water to drip free rather than drain down the surface of the building.

NOTE: Drain kit using either the 90° elbow tube or the straight tube may be installed without modification when using RAG60 exterior grille. Drain kit using the 90° elbow tube may be installed without modification when using RAG61 through RAG66 exterior grilles. Modification must be made to the RAG61 through RAG66 exterior grilles when using the straight tube. Modification must be made to the RAG67 grille if using either the 90° elbow tube or the straight tube (see installation instructions with the RAG67 grille).

MIN. 2 SUPPORTS FIELD SUPPLIED

FLOOR

35

36

WALL CASE WITH RAD10 DRAIN KIT

INTERNAL DRAIN SEE PAGE 35 FOR EXTERNAL DRAIN

SEE DETAIL BELOW OVERFLOW RELIEF DRAIN SEE NOTE 6 SQUARE DRAIN HOLES NEOPRENE SPONGE GASKET STEEL MOUNTING PLATE

USE TYPE "A" SCREW FOR METAL CASE (RAB71) AND TYPE "B" SCREW FOR MOLDED CASE (RAB77) GASKET 1. THE RAD10 DRAIN KIT IS INSTALLED IN THE BOTTOM OF THE WALL CASE WHEN IT IS DESIRED TO DRAIN CONDENSATE TO AN INTERNAL DRAIN SYSTEM IN THE BUILDING. 2. THE DRAIN KIT IS MOUNTED ON THE BOTTOM OF THE WALL CASE PRIOR TO INSTALLATION OF THE CASE IN THE WALL. IT MAY BE LOCATED ANYWHERE ON THE ROOM SIDE PORTION EXCEPT FOR SUB-BASE INSTALLATIONS. FOR THESE THE DRAIN SHOULD BE AT LEAST 3" FROM THE INDOOR EDGE OF THE CASE SO AS TO ADEQUATELY CLEAR THE SUB-BASE. 3. A TEMPLATE IS FURNISHED WITH THE KIT FOR LOCATING THE NECESSARY 3 HOLES IN THE CASE BOTTOM - TWO TO PROVIDE A SECURING MEANS AND ONE TO PROVIDE A DRAIN HOLE FOR THE 1/2" OD TUBING. (SEE DETAILS AT LEFT) 4. A TUBE OR HOSE 1/2" I.D. (OBTAINED LOCALLY) MUST BE INSTALLED ON THE DRAIN TUBE AND CONNECTED TO THE INTERNAL DRAIN SYSTEM IN THE BUILDING. 5. WITH THE RAD10 THE TWO SQUARE DRAIN HOLES IN THE BOTTOM OUTER FLANGE OF THE WALL CASE ARE SEALED BY THE GASKETS AND MOUNTING PLATES SHOWN ABOVE. 6. THREE (3) 1/2" DIAMETER HOLES LOCATED 1/4" ABOVE THE CASE BOTTOM IN THE BOTTOM OUTER FLANGE PROVIDE OVERFLOW DRAINAGE TO THE OUTDOORS WHEN WIND DRIVEN RAIN ENTERS THE CHASSIS. CABINET BOTTOM TUBE 1/2" OD COVER PLATE

NOTE: SHADED PARTS AND SCREWS INCLUDED WITH RAD10 DRAIN KIT. THE 90° ELBOW TUBE IS RECOMMENDED FOR INTERNAL DRAIN INSTALLATION.

SCREWS

"A"

"B"

METAL

PLASTIC

NUT (MOLDED CASE (RAB77) ONLY)

DETAIL

USE TYPE "A" SCREWS FOR BOTH RAB71 AND RAB77

Ducted Installations

2500 and 3500 Series Zoneline units may be used in ducted installations.

With a ducted installation it is possible to condition the air in two areas that have a common wall separating them. A special adapter mounts on the wall case and a transition piece directs the air from the unit into the adapter. Instructions for mounting the adapter to the wall case are included with the duct adapter. The adapter contains a grille that allows air from the unit to be discharged into the primary room and the adapter connects to a duct extension that allows the air to flow to the adjoining room. Ducting a unit may allow a single unit to be used rather than a separate unit in each room, providing a means of reducing initial equipment cost. The duct may extend a total of 15 feet (with a field fabricated insulated duct extension) in one direction, either to the right or to the left of the unit. A baffle in the adapter allows up to 50% of the discharge air to be delivered to the secondary room. The installation of the wall case and sub-base, if used, is the same for units being ducted as for free-standing units. The duct adapter support bracket overlaps the wall case by 1" and the bracket and mounting screws add approximately 3/8" (3/16" on each side) to the width of the wall case. If less than 1" of the wall case projects into the room it will be necessary to allow for the additional width in the opening for the wall case. The duct adapter mounting brackets should be mounted prior to installing the case in the wall. Refer to pages 38 and 39 for drawings of ducted installations. Prior to the installation of the transition from the room cabinet to the adapter, it will be necessary to remove the discharge grille from the room cabinet. Instructions for this modification are included with the duct adapter.

Mounting Collar and Supply Register RAK602 These components are included in the Duct Extension Kit RAK601. They may be ordered separately for installations where two duct extensions are made from one RAK601 Duct Extension, Mounting Collar and Register RAK601.

Ducted Application Considerations

When designing a ducted application some application considerations to be made include: 1. Do not exceed the 15 foot length maximum for the duct extension. Field supplied duct extension must be completely insulated with minimum of 1/2" insulation 2. The duct must be a straight run. Turns or bends in the duct extension create air pressure drops that the unit is not designed to overcome. 3. Minimum recommended clearance between the unit and the adjacent wall is 2". 4. Provisions for return air must be made to allow air circulation from secondary room. Doors in both secondary and primary rooms may be undercut or a return grille may be installed through a common wall. 5. When calculating the heat gain / heat loss take both areas into consideration.

Replacements of Existing Ducted Units

Since the design of the Zoneline chassis has changed over the years to provide better performance and appearance, some of the components used in ducted applications have changed. Select the proper components from the information below. The best procedure in determining the correct kit is to measure duct extension cross section.

New Ducted Installations

Components

Duct Adapter RAK6052 - The duct adapter is secured to each side of the wall case and requires the drilling of mounting holes in the wall case during installation. A template for the hole location is in the installation instructions. By securing the duct Duct Adapter RAK6052 adapter to the wall case, the chassis retains the slide-out feature for servicing after the transition piece is removed. Duct Extension RAK601 - This kit contains a 44" long insulated duct, a register mounting collar, and an air supply register. It can be secured to the duct adapter at either end of the adapter. This duct may be cut at any dimension and used in two applications providing the sum of the two duct lengths necessary do not exceed the 44" length. Even in single applications the mounting flange must be cut off one end of the duct to accept the collar and supply register.

Flat Top-Discharge Units (Zoneline Units Built Prior to 1988)

Existing Duct Extension Cross Section Measurements: 8-3/8" height x 6-1/2" width Duct Adapter RAK7012 - This duct adapter will allow the replacement of a new chassis (2500 or 3500 Series unit) into an existing ducted application. This adapter will align properly with the duct extension and will eliminate the need to modify the wall opening. In order to minimize replacement costs, some of the components of the old duct adapter must be removed and used in the new installation. Consult the Installation Instructions of the RAK7012 before removing and discarding the old duct adapter. See additional notes page 58.

Slope-Front Discharge Units

(Models With AZC, AZR, AZW, or AZ21 or AZ31 Prefix)

Existing Duct Extension Cross Section Measurements: 7-3/32" height x 6-1/2" width Duct Transition RAK7022 - This duct transition will allow the replacement of a new slope-front discharge Zoneline chassis (2500 or 3500 Series unit) into a previous design slope-front ducted installation. See additional notes page 58.

37

38

DUCTED APPLICATION (AZ2500/3500 SERIES)

44" RAK601 44" LENGTH RAK6052 ADAPTER 8" high TRANSITION

8" 3/ 7- de i w

RECOMMENDED MINIMUM CLEARANCE 2" TO SIDE WALL

NOTES:

1. RAK6052 kit includes duct adapter, transition and mounting hardware.

2. RAK601 duct extension may be installed at either end of the RAK6052 duct adapter. Maximum duct extension length is 15'. Duct extension must be field fabricated for installations where length of duct exceeds length of RAK601 (44"). Field fabricated duct extension must be insulated to prevent condensation from forming on exterior. Duct extension may not contain bends or turns.

3. Ducted units may need to be permanently connected. Check local code for specific electrical installation requirements.

4. Duct extension kit RAK601 contains 44" duct extension, discharge grille mounting collar, and discharge grille. Duct extension must be cut to required length. Two ducted installations may be made from one kit if the combined ducted length is less than 44". RAK602 kit contains mounting collar, discharge grille and mounting hardware necessary for second installation.

DUCT ADAPTER EXTENSION HAS 1/2" INSULATION

5. Filler strip (field supplied) actual width depends upon wall case projection into room. A flush installation to finished wall (i.e., no filler strip) can be made.

6. Unit must be installed to provide at least a 2" clearance between side of unit and wall.

7. Provisions for return air must be made in order to allow air circulation from secondary room. Doors in both secondary and primary rooms may be undercut or a return grille may be installed through common wall.

8. For replacement of previous design units, see pages 37 and 58.

DUCTED DETAILED SIDE VIEWS (AZ2500/3500 SERIES)

SEE PAGE 38 FOR ALL NOTES

Line Cord Installation

Sub-Base Installation

ANY CONSTRUCTION 2-3/8"* MIN. 6-1/2" 11-1/8" MAX. 12-3/4" MAX.

6-1/2"

RAK6052 ADAPTER 7-3/32" RAK6052 ADAPTER

10"

7-3/32"

2-29/32" 2-29/32"

1/4" MIN.

1/4"

TRANSITION

3/4" MIN. WALL TO CASE EDGE

TRANSITION

Caulk around perimeter of wall case all four sides where it joins the building Interior and Exterior. WALL CASE

16-1/8" WALL CASE

16-1/8" ROOM CABINET

FINISHED FLOOR

FINISHED FLOOR 3" MIN. 5" MAX. CAULK* RAK 204

RECEPTACLE CAULK* (BY OTHERS ALT. LOCATIONS)

RAG60 - 1/4" RAG61-66 - 1-3/8"

FILLER STRIP (SEE NOTE 5 ON PAGE 36)

ROOM CABINET

RAG60 - 1/4" RAG61-66 - 1-3/8"

3-11/16"

*Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.

*2-3/8" min. when installed with RAK204.

39

Exterior Grilles

Four styles of outdoor grilles are available for exterior treatments. The standard stamped aluminum grille (RAG60), the molded architectural louvered exterior grilles (RAG61-63), the molded architectural louvered exterior grilles with flange (RAG64-66), and the extruded aluminum architectural louvered grille (RAG67). All grilles include air deflectors and gaskets to prevent condenser air recirculation. RAG60 Outdoor Grille The standard exterior grille is made of durable aluminum to protect chassis components and prevent air recirculation.

Replacement of existing units: If an existing grille is not replaced, capacity and efficiency will be reduced and the unit may fail to operate properly or fail prematurely. A deflector kit, RAK40, may be used with grilles that were not designed for current AZ Series GE Zoneline units. The RAK40 contains air deflectors and gaskets that mount to the chassis to direct the hot exhaust air away from the air intake to allow the unit to function properly. All grilles used with GE Zoneline units must comply with requirements of Exterior Architectural Treatments and Special Outdoor Grilles. as follows.

RAG60 Outdoor Grille

Exterior Architectural Treatments and Special Outdoor Grilles

The architectural design of a building may dictate the use of special or oversized louvers for aesthetic reasons. Louvers other than standard Zoneline exterior grilles may be used on the Zoneline unit, however, these special louvers, or any special exterior architectural treatments of the building facade that may restrict the free circulation of condenser airflow, should be referred to GE Application Engineering for evaluation and approval. The following guidelines should be followed in selecting a louver: 1. The louver must have a minimum of 65% free area. ASHRAE defines free area as the minimum area of the opening in an air inlet or outlet through which air can pass. Percent (%) free area equals the X dimension divided by the Y dimension. 2. The louver should be attached to the wall case in a manner that will prevent recirculation of condenser discharge air into the air inlet. If the louver is not attached directly to the wall case, a field supplied splitter or gasket is required between the chassis and the louver to prevent recirculation. It is important that the above criteria be followed since a louver that is too restrictive or allows recirculation will reduce the unit's capacity and efficiency, increase the electrical current draw, cause intermittent operation due to the compressor overload protector shutting the compressor off, and cause failure of the compressor overload and shorten compressor life. Using the unit with a grille that is too restrictive or allows recirculation may constitute improper installation. A scale drawing of the louver section should be sent to GE Application Engineering. To assure the proper performance of the Zoneline unit and comply with Underwriters Laboratories requirements, it may be necessary to send a sample louver section (at least 16" x 42") to GE to be tested with the Zoneline unit. Sample Calculations x x 100 x = 1" y F.A. % = 1 x 100 = 66.7% 1.5

RAG61, 62, 63 Architectural Grille - One piece optional molded grille and frame assembly provides improved appearance, protection and weatherability. Molded of durable polycarbonate, the surfaces of the grille have a colorfast, slightly textured finish which blends well RAG61 Outdoor Grille with most types of wall surfaces. The grilles can be painted in the field to match the building for improved aesthetics. RAG64, 65, 66 Architectural Grille with Flange - Identical to RAG61-63 grilles with the addition of a 1/2" flange around the top and sides to help conceal the juncture of the RAB71 wall case and the wall opening. The best RAG64 Outdoor Grille appearance is achieved with this grille when the wall case extends minimally (between 1/4" and 1/2") beyond the exterior face of the building. Colors: RAG61 and 64 - Beige; RAG62 and 65 - Dark Maple RAG63 and 66 - Bittersweet Chocolate. RAG67 Extruded Aluminum Grille - The RAG67 is made from extruded anodized aluminum for use where an aluminum architectural grille is preferred. The RAG67 is available in a RAG67 clear finish and may be special ordered from GE in other colors. Minimum order quantities may be required. Contact your General Electric salesperson for details. All grilles are installed and secured to the wall case from the inside. Keyhole slots in the rear flange of the case allow the grille to be placed in position before securing it firmly to the wall case.

Free Area (%) =

y = 1.5"

40

Power Connection For Deluxe Series (2500 & 3500)

The Zoneline 2500 and 3500 Series units have discrete heater wattages. Each unit has a factory installed heater and must be installed on an electrical circuit with sufficient over-current protection to carry the amperage load of the unit. See specifications on page 54 for model number nomenclature, heater amperage, and minimum circuit ampacity for the particular Zoneline model. To determine maximum connected load for individual model see page 44. 230/208 Volt Unit Installation - Line Cord Connected Units Zoneline 2500 and 3500 series units for installation on 230 or 208 volt circuits have a factory installed line cord with a plug conforming to NEC standards for the circuit amperage. Graphic representation of the wall receptacles are shown on page 42. The line cord length is also shown on page 42. 230/208 Volt Unit Installation - Permanent Connected Units If a permanent, or direct wired, installation of a 230 or 208 volt units is desired, a junction box kit, RAK4002A, is available to allow direct connection when the 208/230 volt chassis is installed with the appropriate electrical sub-base. When the cord set is enclosed by the RAK4002A and the sub-base chase way RAK205CW, the wiring is totally enclosed and the unit is considered to be permanently connected (correct ampacity RAK204 series sub-base required). If an installation using flexible conduit is desired, the RAK4002A kit mounts to the chassis to form an enclosed junction box with a removable front panel for access to the unit wiring. A 7/8" diameter hole in the bottom of the enclosure enables field supplied rigid or flexible conduit to be connected to the kit. A wiring harness of three conductors and an in-line connector is included with the RAK4002A. The factory installed line cord must be cut off approximately 8" from where it comes through the barrier, or bulkhead, of the unit. Strip insulation off 3/4" of each conductor to expose wire for field connection. These wires are then connected to the building wiring by field supplied connectors. 265 or 277 Volt Unit Installation - Permanent Connected Units National Electric Code (Article 440 Section G) requires permanent connection for units connected to power sources over 250 volts, therefore these units must be permanently connected (direct wired). Zoneline 2500 or 3500 Series units rated for installation on 265 volt circuits have discrete heater wattages and the appropriate cord set to match the 265 volt sub-base receptacle installed in this sub-base. When installed with the correct sub-base and chaseway the wiring is totally enclosed and the installation is considered to be permanently connected. If there are any questions regarding electrical connection at the unit GE recommends consulting with your local electrical inspector. A junction box is included with every 265/277 volt chassis to facilitate the installation of conduit if desired. A 7/8" diameter hole in the bottom of the RAK4002A junction box enables field supplied rigid or flexible conduit to be connected to the unit. A knockout is provided in the junction box for the installation of a field supplied cartridge type fuse, if required. A wiring harness of three conductors and an inline connector is included with the RAK4002A. This wiring harness can be ordered separately as RAK4002CW to facilitate chassis removal. When direct connecting the unit, connections to the building wiring should be made in the junction box with field supplied connectors. All wiring must conform to local electrical regulations and codes.

RAK4002A Wire harness can be ordered separately with RAK4002CW

41

Power Connection Kits For Premium Series (5500)

The Zoneline 5500 Series units are connected to the building power supply by a unique power connection kit. By utilizing a separate universal power connection (UPC) kit, each unit is capable of providing various outputs of electric resistance heat to more closely meet the heating requirements of the particular room, thereby increasing the installation flexibility of the particular chassis. This power connection kit is the only means of supplying power to the Zoneline chassis and the appropriate kit is determined by the voltage and the desired resistance heat output that may be supported by the branch circuit. Permanent Connection is accomplished by ordering the correct ampacity electrical sub-base to match the Power Cord Kit being used. See page 23 Sub-Base for description. There may be special requirements by some sites that rigid or flexible conduit be used. (Such as the wall case must be installed flush to finished floor and there is no room for a sub-base.) In these installations the RAK4002B junction box will be needed and the Power Cord/Cord Set will be cut and connected to building wiring inside the RAK4002B junction box. Conduit will be attached to the RAK4002B and to the site supplied building/room junction box where the building wiring enters the room. Wiring will be totally enclosed by conduit and junction boxes.

230/208 Volt Installations

Connections to 208 or 230 volt circuits may be made with a line cord power connection kit. Line Cord Kits consist of a self-aligning 9-pin molded connector that plugs into a mating connector on the Zoneline chassis and insulated line cord with an electrical plug on the end. The configuration of the electrical plug conforms to NEC standards for the circuit amperage and the postion of the wires in the 9-pin connector determines the heater wattage and current requirements when it is plugged into the Zoneline chassis.

Line Cord Kit Voltage RAK3152 230/208

Heater KW 2.55/2.09

Circuit Ampacity 15 Amp

Protective Device 15 Amp Time Delay Fuse or Breaker 20 Amp Time Delay Fuse or Breaker 30 Amp Time Delay Fuse or Breaker

RAK3202

230/208

3.45/2.82

20 Amp

RAK3302

230/208

5.00/4.09

30 Amp

Premium Typical Line Cord Power Connection Kit Maximum Cord Extension

Type 15 AMP Tandem NEMA6-15R 20 AMP Perpendicular NEMA6-20R 30 AMP Large Tandem NEMA6-30R

Mfg

Receptacle Part No GE4069 5661 5661 GE4182 5461 5871 9330 5930

Configuration

GE Hubbell P&S GE Hubbell P&S Hubbell P&S

42

Power Connection Kits For Premium Series (5500)

265 or 277 Volt Installations

National Electrical Code (Article 440 section G) requires permanent connection for installation on circuit in excess of 250 volts. Permanent Connection Kits are available for 265 volt installations. The regular kit consists of a self-aligning 9-pin connector that plugs into a mating connector on the chassis, a length of power cord with the plug cap molded to the end. There are four 265 volt cord sets so that the desired heater KW will be achieved when the correct RAK5*** kit is selected. See chart below for guide. These cord sets will match the receptacle in the RAK204E Series sub-base. It is important that care be used in this selection process. This cord set, when used with the appropriate sub-base with provided chase way from the junction box to the sub-base, is considered to be permanently connected. For those installations that require a method of direct connection using flexible or rigid conduit, the RAK4002B junction box (provided with chassis) can be used and the field supplied conduit attached to it. The universal cord set will be cut off and connections made inside the junction box. See page 44 for total connected load for 5500 series units.

Line Cord Connected Units

The plug configuration of new line cord connected units complies with the current NEC standards. Older installations may have wall receptacles that conformed to NEC standards at the time the building was constructed and may not match the configuration of the plug on the new line cord. Recommended solution is to change the wall receptacle to conform to current standard plug configuration. See chart on page 42 for current receptacle configuration.

Permanent Connected Units With Sub-base

If the existing unit is connected to a sub-base the installation of the new unit may involve modifying the existing installation slightly. It is recommended these modifications be made by a qualified electrician. If the existing sub-base is the full width of the wall case, RAK201 sub-base access plate may be ordered and used to replace the cover on the old sub-base. Field supplied wiring, conduit and conduit connectors should be used to make connection between new chassis and the center knockout of the RAK201. The wiring connections should be made inside the sub-base and the RAK201 attached to the sub-base with the 2 screws provided. If the existing sub-base is not the full width of the wall case the electrician will have to modify the existing cover plate to allow field supplied wiring, conduit, and conduit connectors to be run from the permanent connection kit to the sub-base.

Permanent Connection Kit Voltage Heater Circuit KW Ampacity Protective Device (Fuse Included)

Electrical Wiring Information - 2500/3500/5500 Series

All Zoneline units are single phase 60 hertz units. For all installations feeder, sub-feeder, branch circuit and electrical protective devices and selection must conform to the National Electrical Code and to local codes. Maximum connected load in amperes, including demands for the electric heater and the fan motor, are shown on page 44. Branch circuit ampacity and electrical protective device sizing are shown on page 42 for 230/208 volt units and on this page for 265 volt units. (Although presented with Premium 5500 Series this information also is valid for Deluxe Series 2500 and 3500 Series units.) More than one unit per branch circuit is not recommended; however, when in doubt, consult the National Electrical Code. All wiring, including installation of receptacle, must conform to local electrical regulations and codes.

RAK5152 RAK5172 RAK5202 RAK5302

265 265 265 265

1.7 3.0 3.7 5.0

15 Amp 15 Amp 20 Amp 30 Amp

15 Amp 15 Amp 20 Amp 30 Amp 15 Amp 20 Amp 30 Amp

NEMA7-15R; receptacle used on 265V sub-base GE0715 NEMA7-20R; receptacle used on 265V sub-base GE0720-3 NEMA7-30R; receptacle used on 265V sub-base GE073

Replacement of Existing Chassis

230/208 Volt and 265 Volt Units

There have been changes to NEC and improvements and modifications to the Zoneline chassis and sub-bases since the unit was first introduced. Some of these changes require alterations to be made when replacing an older unit with a new chassis.

RAK4002B Installed

RAK4002B

43

Maximum Connected Load For Deluxe Series (2500 and 3500)

The maximum connected load of a Zoneline unit occurs when the unit is in resistance heating operation. The maximum amperage shown in the tables below is the combined total of the resistance heater and the indoor fan motor.

Model Number AZ25E07D2* AZ25E07D3* AZ25E09D2* AZ25E09D3* AZ25E09D5* AZ25E12D2* AZ25E12D3* AZ25E12D5* AZ25E15D2* AZ25E15D3* AZ25E15D5* AZ35H07D2* AZ35H07D3* AZ35H09D2* AZ35H09D3* AZ35H09D5* AZ35H12D2* AZ35H12D3* AZ35H12D5* AZ35H15D2* AZ35H15D3* AZ35H15D5* 230 V Watts 2600 3500 2610 3510 5060 2620 3520 5070 2630 3520 5080 2600 3500 2610 3510 5060 2620 3510 5070 2630 3530 5080 208 V Watts 2130 2860 2140 2870 4140 2150 2880 4150 2160 2890 4160 2130 2860 2140 2870 4140 2150 2880 4150 2160 2890 4160 Model Number AZ25E07E3* AZ25E07E4* AZ25E09E3* AZ25E09E4* AZ25E09E5* AZ25E12E3* AZ25E12E4* AZ25E12E5* AZ25E15E3* AZ25E15E4* AZ25E15E5* AZ35H07E3* AZ35H07E4* AZ35H09E3* AZ35H09E4* AZ35H09E5* AZ35H12E3* AZ35H12E4* AZ35H12E5* AZ35H15E3* AZ35H15E4* AZ35H15E5* 265 V Watts 2600 3750 2610 3760 5060 2620 3770 5070 2630 3780 5080 2600 3750 2610 3760 5060 2620 3770 5070 2630 3780 5080

Amps 11.4 15.3 11.4 15.3 22.0 11.5 15.4 22.1 11.5 15.4 22.1 11.4 15.3 11.4 15.3 22.0 11.5 15.4 22.1 11.5 15.4 22.1

Amps 10.2 13.8 10.3 13.9 20.0 10.3 13.9 20.0 10.4 14.0 20.1 10.2 13.8 10.3 13.9 20.0 10.3 13.9 20.0 10.4 14.0 20.1

Amps 9.8 14.3 9.9 14.3 19.2 9.9 14.3 19.2 9.9 14.3 19.2 9.8 14.3 9.9 14.3 19.2 9.9 14.3 19.2 9.9 14.3 19.2

Maximum Connected Load For Premium Series (5500) 230/208 V

Model Number AZ55H07DA* AZ55H09DA* AZ55H12DA* AZ55H15DA* With RAK3152 Watts/Amps 230V 208V 2615/11.4 2145/10.3 2615/11.4 2145/10.3 2640/11.5 2165/10.4 2685/11.7 2210/10.6 With RAK3202 Watts/Amps 230V 208V 3515/15.3 2880/13.9 3515/15.3 2880/13.9 3540/15.4 2900/14.0 3585/15.6 2945/14.2 With RAK3302 Watts/Amps 230V 208V 3515/15.3** 2880/13.9** 5065/22.0 4150/20.0 5090/22.1 4170/20.1 5135/22.3 4215/20.3

Maximum Connected Load For Premium Series (5500) 265V

Model Number AZ55H07EA* AZ55H09EA* AZ55H12EA* AZ55H15EA* With RAK5152*** Watts/Amps 2235/8.6 2400/9.1 2670/10.3 2965/11.4 With RAK5172 Watts/Amps 3075/11.6 3075/11.6 3100/11.7 3135/11.8 With RAK5202 Watts/Amps 3775/14.3 3775/14.3 3800/14.4 3835/14.5 With RAK5302 Watts/Amps 3775/14.3** 5075/19.2 5100/19.3 5135/19.4

* ** ***

Covers all model versions. AZ55H07 does not have 5 kW heater. Maximum connected load occurs when this unit with this power connection kit is in simultaneous operation of heat pump with supplemental 1700 watt heater.

44

Cooling Performance Data

Total Capacity - BTU/Hr. BTUH At 80°F D.B. - 67°F W.B.

Zoneline 2500 Series

Temperature of Air Entering Condenser 75 82 85 95 105 115 AZ 25E07D 25E07E 7750 7580 7500 7100 6600 6000 AZ 25E09D 25E09E 9900 9690 9600 9000 8250 7500 AZ 25E12D 25E12E 12800 12590 12500 11700 10750 9650 AZ 25E15D 25E15E 15900 15620 15500 14600 13600 12300

Zoneline 3500 Series

AZ 35H07D 35H07E 7750 7580 7500 7100 6600 6000 AZ 35H09D 35H09E 9900 9690 9600 9000 8250 7500 AZ 35H12D 35H12E 12800 12590 12500 11700 10750 9650 AZ 35H15D 35H15E 15900 15620 15500 14600 13600 12300

Zoneline 5500 Series

AZ 55H07D 55H07E 7750 7580 7500 7100 6600 6000 AZ 55H09D 55H09E 9900 9690 9600 9000 8250 7500 AZ 55H12D 55H12E 12900 12690 12600 11800 10850 9750 AZ 55H15D 55H15E 16000 15720 15600 14700 13700 12400

Heat Pump Performance Data

Capacities and COP at Various Outdoor Temperatures BTUH At 70°F Indoor Temperature

Zoneline 3500 Series

AZ35H07D Outdoor Temperature F° 65 60 55 50 47 45 40 35 30 25 AZ35H07E BTUH 7200 7000 6800 6600 6400 6250 5950 5550 5150 4700 COP 3.75 3.70 3.65 3.55 3.50 3.45 3.35 3.20 3.05 2.90 AZ35H09D AZ35H09E BTUH 10000 9600 9100 8700 8400 8200 7700 7100 6500 5900 COP 3.75 3.70 3.65 3.55 3.50 3.45 3.30 3.20 3.05 2.85 AZ35H12D AZ35H12E BTUH 13050 12550 11950 11350 10900 10600 9800 9000 8200 7300 COP 3.55 3.50 3.45 3.35 3.30 3.25 3.10 3.00 2.85 2.65 AZ35H15D AZ35H15E BTUH 15950 15300 14650 13850 13400 13050 12250 11300 10300 9250 COP 3.35 3.30 3.25 3.15 3.10 3.05 2.95 2.80 2.65 2.50

Zoneline 5500 Series

AZ55H07D Outdoor Temperature F° 65 60 55 50 47 45 40 35 30 25 AZ55H07E BTUH 7200 7000 6800 6600 6400 6250 5950 5550 5150 4700 COP 3.75 3.70 3.65 3.55 3.50 3.45 3.35 3.20 3.05 2.90 AZ55H09D AZ55H09E BTUH 10000 9600 9100 8700 8400 8200 7700 7100 6500 5900 COP 3.75 3.70 3.65 3.55 3.50 3.45 3.30 3.20 3.05 2.85 AZ55H12D AZ55H12E BTUH 13050 12550 11950 11350 10900 10600 9800 9000 8200 7300 COP 3.55 3.50 3.45 3.35 3.30 3.25 3.10 3.00 2.85 2.65 AZ55H15D AZ55H15E BTUH 15950 15300 14650 13850 13400 13050 12250 11300 10300 9250 COP 3.35 3.30 3.25 3.15 3.10 3.05 2.95 2.80 2.65 2.50

45

Latent System Capacity

The total capacity of an air conditioner is made up of the Sensible capacity, the output of the unit used to remove heat from the air in the area being conditioned, and the Latent capacity, the output of the unit used to dehumidify the air in the area being conditioned. For humid climates and applications, the Sensible/Latent capacity split of the unit should be considered. The Sensible capacity listed in the specification charts on pages 52 and 53 are at standard rating conditions of 95°F. dry bulb/75°F. wet bulb outdoors; 80°F. dry bulb/67°F. wet bulb indoors. The Latent system capacity is 1.00 minus the Sensible capacity. (If the Sensible capacity is listed at .74 the Latent capacity is .26. This means that 74% of the capacity of the unit is used to remove heat from the air and 26% is used to remove moisture from the air at standard test conditions).

AZ25E07D/E AZ55H07D/E

60 L a t e n t % o f T o t a l 30 67 °F W.B. 50

Indoor Wet Bulb Temp

In some applications information about the Sensible/Latent split, or ratio, at conditions other than the standard rating conditions is needed. The charts below provide data at various indoor conditions. To use the charts, first determine which Zoneline model is being considered and refer to the appropriate chart. Next, locate the indoor dry bulb temperature under consideration across the horizontal axis of the chart and draw a line straight up until it touches the line representing the indoor wet bulb temperature of the area; from this point draw a horizontal straight line to the vertical axis. The point where the line touches the axis represents the latent percent of the total capacity of the unit. An example is shown for the standard indoor conditions of 80°F. dry bulb/67°F. wet bulb.

AZ25E09D/E AZ55H09D/E

60 L a t e n t % o f T o t a l 30 67 °F W.B. 50

Indoor Wet Bulb Temp

AZ35H07D/E SHR 74%

AZ35H09D/E SHR 67%

40

71°F W.B.

40

71°F W.B.

20 63°F W.B. 10 59°F W.B. 0 60 65 70 75 80 85 90 95 100 105 °F Degrees (Indoor Dry Bulb)

20 63°F W.B. 10 59°F W.B. 0 60 65 70 75 80 85 90 95 100 105 °F Degrees (Indoor Dry Bulb)

AZ25E12D/E AZ55H12D/E

60 L a t e n t % o f T o t a l 30

AZ35H12D/E SHR 65%

60 67 °F W.B. L a t e n t % o f T o t a l 30

AZ25E15D/E AZ55H15D/E

AZ35H15D/E SHR 65%

67 °F W.B.

50

Indoor Wet Bulb Temp

50

Indoor Wet Bulb Temp

40

71°F W.B.

40

71°F W.B.

20 63°F W.B. 10 59°F W.B. 0 60 65 70 75 80 85 90 95 100 105 °F Degrees (Indoor Dry Bulb)

20 63°F W.B. 10 59°F W.B. 0 60 65 70 75 80 85 90 95 100 105 °F Degrees (Indoor Dry Bulb)

46

Normal Yearly Operating Data

Location ASHRAE Heating Degree Days Estimated Cooling Hours Location

(Cooling Hours based on 75°F. indoor temperature with air conditioner sized to meet the design conditions.)

ASHRAE Heating Degree Days Estimated Cooling Hours Location ASHRAE Heating Degree Days Estimated Cooling Hours

ALABAMA Birmingham Huntsville Mobile Montgomery ARIZONA Flagstaff Phoenix Tucson Yuma ARKANSAS Fort Smith Little Rock CALIFORNIA Bakersfield Fresno Los Angeles Sacramento San Diego San Francisco COLORADO Colorado Springs Denver Grand Junction CONNECTICUT Hartford D.C. Washington DELAWARE Wilmington FLORIDA Jacksonville Miami Orlando Tallahassee Tampa GEORGIA Atlanta Augusta Macon Savannah IDAHO Boise Lewiston Pocatello ILLINOIS Chicago Moline Springfield INDIANA Evansville Fort Wayne Indianapolis South Bend IOWA Burlington Des Moines Sioux City KANSAS Dodge City Goodland Topeka Wichita

2,551 3,070 1,560 2,291 7,152 1,765 1,800 974 3,292 3,219 2,122 2,611 2,061 2,502 1,458 3,015 6,423 6,283 5,641 6,235 4,224 4,930 1,239 214 766 1,485 683 2,961 2,397 2,136 1,819 5,809 5,542 7,033 6,155 6,408 5,429 4,435 6,205 5,699 6,439 6,114 6,588 6,951 4,986 6,141 5,182 4,620

1,390 1,340 1,640 1,580 310 2,280 1,920 2,520 1,410 1,330 1,530 1,210 310 1,030 390 110 520 550 910 480 1,010 770 1,690 2,850 1,930 1,500 2,350 1,130 1,400 1,440 1,510 670 600 570 780 760 890 1,090 710 820 600 730 710 770 1,020 800 880 1,070

KENTUCKY Lexington Louisville LOUISIANA Alexandria Baton Rouge New Orleans Shreveport MAINE Portland MARYLAND Baltimore MASSACHUSETTS Boston MICHIGAN Detroit Flint Grand Rapids MINNESOTA Duluth Minneapolis MISSISSIPPI Jackson MISSOURI Columbia Kansas City Springfield St. Louis MONTANA Billings Glasgow Great Falls Missoula NEBRASKA Grand Island Omaha NEVADA Ely Las Vegas Reno NEW JERSEY Newark NEW MEXICO Albuquerque Clayton Silver City NEW YORK Albany Binghamton Buffalo New York Rochester Syracuse NORTH CAROLINA Asheville Charlotte Raleigh Winston-Salem NORTH DAKOTA Bismarck Fargo Williston

4,683 4,660 1,921 1,560 1,385 2,184 7,511 4,654 5,634 6,293 7,377 6,894 10,000 8,382 2,239 5,046 4,711 4,900 4,900 7,049 8,996 7,750 8,125 6,530 6,612 7,733 2,709 6,332 4,589 4,348 5,158 3,705 6,875 7,286 7,062 4,811 6,748 6,756 4,042 3,191 3,393 3,595 8,851 9,226 9,243

830 1,130 1,670 1,860 1,790 1,470 290 850 500 590 440 530 200 550 1,560 960 1,210 970 1,080 520 410 420 350 770 750 500 1,980 520 710 1,040 720 1,260 480 310 450 790 470 500 690 1,230 1,070 960 510 490 580

OHIO Cincinnati Cleveland Columbus Dayton Toledo OKLAHOMA Oklahoma City Tulsa OREGON Medford Pendleton Portland PENNSYLVANIA Harrisburg Philadelphia Pittsburgh Scranton Williamsport RHODE ISLAND Providence SOUTH CAROLINA Charleston Columbia Greenville SOUTH DAKOTA Rapid City Sioux Falls TENNESSEE Chattanooga Knoxville Memphis Nashville TEXAS Corpus Christi Dallas El Paso Houston Lubbock San Antonio UTAH Milford Salt Lake City VERMONT Burlington VIRGINIA Norfolk Richmond Roanoke WASHINGTON Seattle Spokane Yakima WEST VIRGINIA Charleston Huntington WISCONSIN Madison Milwaukee WYOMING Casper Cheyenne Sheridan

5,265 6,351 5,660 5,622 6,494 3,725 3,860 5,008 5,127 4,635 5,251 5,144 5,987 6,254 5,934 5,954 2,033 2,484 2,980 7,345 7,839 3,254 3,494 3,232 3,578 914 2,363 2,700 1,396 3,578 1,546 6,497 6,052 8,269 3,421 3,865 4,150 5,145 6,655 5,941 4,476 4,446 7,863 7,635 7,410 7,381 7,680

840 610 810 740 590 1,200 1,410 620 590 270 730 810 590 440 600 470 1,390 1,440 1,120 580 610 1,180 1,070 1,320 1,220 2,380 1,900 1,580 1,850 1,310 1,920 910 830 130 1,010 1,020 870 180 430 530 860 820 530 450 600 420 530

Formula for Calculating Operating Costs Using Above Data:

Heat Loss KW x Heating Degree Days x "C" x Cost per KWH = Operating Cost Outdoor Design Temperature Difference *The above formula is for electric resistance heating only. Power consumption using the Zoneline Heat Pumps should be adjusted by Seasonal Performance Factor (SPF). Heating* The local power supplier should be consulted for recommended value of "C." This factor will vary between 17 and 24. Cooling Calculated Heat Gain (BTUH) x Unit Cooling Watts Installed unit capacity (BTUH) 1000 Watts/KW x Cooling Hours x Cost per KWH = Operating Cost

47

Typical 2500 Series Wiring Diagram

ROOM ID. COIL HEATER BL GY YL OR OR YL WH 5 6 BK RY102 CN104 RY101 O. L. P. GY (RIB SIDE) R RD RUNNING CAPACITOR

RY107 RY106 RY105 RY104 RY103 CN1 RY102 RY101

PROTECTOR BL HEATER UNIT

FUSE

1

2

3

4

GR

CN1 CN5

CN2

MAIN BOARD UNIT

CN3 1 WH 2 WH

CN8 NR101 CN102 1 3 5 1 3 5 RY103 Varistor RD WH BK

OD. FAN MOTOR

YL YL

1 2 CN103

CN101

DRIVE BOARD UNIT

C S WH

ID. FAN MOTOR RD WH BK RD BK

CM

FM

YL BR RUNNING CAPACITOR

BK TRANSFORMER COLOR BK : BLACK BL : BLUE BR : BROWN GR : GREEN GY : GRAY OR : ORANGE RD : RED WH : WHITE YL : YELLOW BK

5 7

Typical 2500 Series Schematic Diagram

(HEATER UNIT) HEATER R COMP. MOTOR S RUNNING CAPACITOR FAN MOTOR CAPACITOR FUSE FAN MOTOR CAPACITOR PROTECTOR

OUTDOOR FAN MOTOR INDOOR FAN MOTOR

O. L. P.

C

CN102 RY107 RY102 RY101 FUSE (FU101) Varistor (NR101) CN103 RY103 RY106

CN101 RY104 RY105

TRANSFORMER

(TR1)

Capacitor (C101. C102)

CN8

DRIVE BOARD UNIT

REGULATOR

CN3 SELECT SW DECODER HEAT H HEAT A OFF FAN L FAN H COOL A COOL H THERMO CONTROL INTERFACE (for setting) DIP SW

REMOTE T' STAT CDC TRANSFER FAN MOTION SENSOR DOOR SWITCH CN5

ROOM ID. COIL

MAIN BOARD UNIT

48

CN104

CN2

CONTROL CIRCUIT

COMPRESSOR

FM

BL GY RUNNING CAPACITOR

BK

Typical 3500 Series Wiring Diagram

ROOM ID. COIL OD. COIL HEATER BL GY WH GR BK RY102 CN104 RY101 CN105 O. L. P. 1 3 1 3 5 1 REV. VALVE SOLE. BL GY RUNNING CAPACITOR YL BR RUNNING CAPACITOR WH GY (RIB SIDE) R RD RUNNING CAPACITOR (OPTIONAL) ICR 1 YL 3 YL COMPRESSOR

(OPTIONAL) ICR PUMP

PROTECTOR BL HEATER UNIT

FUSE

OR 4

BK 5

YL

1

YL OR

2

3

CN1 CN5

CN2

MAIN BOARD UNIT

CN3 1 WH 2 WH

BK 6

RD*1 RD*1

RV

OD. FAN MOTOR

CN8 NR101 Varistor

CN102

RD WH BK

FM

ID. FAN MOTOR

BK C S

YL YL

1 2 CN103

CN101

DRIVE BOARD UNIT

RY103

CM

BK TRANSFORMER BK

5 7

RD 3 WH 5 BK RD BK

FM

COLOR BK : BLACK BL : BLUE BR : BROWN GR : GREEN BR GY : GRAY OR : ORANGE RD : RED WH : WHITE YL : YELLOW RD*1: RED(208/230V), BLUE(265V)

CN107 CN203 1 2 CN202

CN106 1 3 RD RD CN201

ICR BOARD UNIT (OPTIONAL)

PM

Typical 3500 Series Schematic Diagram

(HEATER UNIT) HEATER R COMP. MOTOR S RUNNING CAPACITOR FAN MOTOR CAPACITOR FUSE FAN MOTOR CAPACITOR PROTECTOR

INDOOR FAN MOTOR REVERSE VALVE SOL.

O. L. P.

C

OUTDOOR FAN MOTOR

CN102 RY107 RY102 RY101 FUSE (FU101) Varistor (NR101) CN103 RY103 RY106

CN101 RY104 RY105

CN105 RY108

CN201 RY201

TRANSFORMER

(TR1)

Capacitor (C101. C102)

CN8

CN106

DRIVE BOARD UNIT

REGULATOR

ICR BOARD UNIT

CN107 CN203 RY108 CN104 RY107 RY106 RY105 RY104 RY103 RY102 RY101

CN3 SELECT SW DECODER HEAT H HEAT A OFF FAN L FAN H COOL A COOL H THERMO CONTROL INTERFACE CN1 (for setting) DIP SW

(OPTIONAL) CN202

REMOTE T' STAT CDC TRANSFER FAN MOTION SENSOR DOOR SWITCH CN5

RY201

ROOM ID. COIL OD. COIL

MAIN BOARD UNIT

CN2

CONTROL CIRCUIT

49

Typical 5500 Series Wiring Diagram

COLOR BK : BLACK BL : BLUE BR : BROWN GR : GREEN GY : GRAY OR : ORANGE RD : RED WH : WHITE YL : YELLOW RD*1 : RED (208/230V), : BLUE (265V) OD. COIL OUTDOOR ID. COIL HEATER (265V) (208/230V) GY WH 1 2 1 2 BK BR 3 6 3 4 5 4 8 9 5 6 7 9 BL OR O.L.P. C S RUNNING CAPACITOR RY102 RY101 RY109 1 RD*1 3 RD*1 1 RD 3 WH 5 BK 1 3 5 REV. VALVE SOLE. BL GY RUNNING CAPACITOR ID. FAN MOTOR BK R RD HEATER HEATER HEATER FUSE BK PROTECTOR HEATER UNIT

CN202

CM

WH

CN105

OR OR BK BK BL BL RD RD

CN102

YL YL

BK

CN8 NR101

OD. FAN MOTOR

1 CN5

2 3 4 5 6 7 CN1 MAIN BOARD UNIT CN3 CN6 & 7 WH 1

8 9 10 VARISTOR CN104 CN2 DRIVE BOARD UNIT

FM

RD WH BK OR OR 1 2 3 4 6 RD WH BK BL GY

WH

RD

RV

BL WH WH 6 WH WH 3 RD RD 5 RD RD 2 BR BK 4 BK BK 1 RD 2 BK RD 1 BK

CN101

2 WH

YL 1 YL 2 CN103 RY103

FM

CN301 & 302 OPERATION BOARD UNIT TRANSFORMER

5 BK 7 BK

CN107

CN106 1 3 RD RD CN201

RUNNING CAPACITOR RD BL

BR

1 2

CN203 ICR BOARD UNIT (OPTIONAL)

CN202

1 YL 3 YL

PM

ICR (OPTIONAL)

Typical 5500 Series Schematic Diagram

UNIVERSAL CONNECTOR FAN MOTOR CAPACITOR FAN MOTOR CAPACITOR

(OPTIONAL) OUTDOOR FAN MOTOR INDOOR FAN MOTOR REVERSE VALVE SOL. ICR PUMP

R COMP. MOTOR S RUNNING CAPACITOR

PROTECTOR

O. L. P.

C

HEATER UNIT

FUSE

HEATER HEATER HEATER

RY107

RY103

RY106

RY104

RY105

RY108

OPE OPE COOL FAN

RY109

RY102

RY101

DECODER

CN102

CN101

CN105

CN201

RY201

OPERATION BOARD

CURRENT DETECTOR (CT1)

HEAT MODE

TRANSFORMER

LOW AUTO

DRIVE BOARD UNIT

REGULATOR

ICR BOARD UNIT

HIGH

CN103

(TR1)

Varistor (NR101)

Capacitor (C101, C102)

CN8

CN106

FUSE (FU101)

FAN SPEED

THERMO

CN3

UP DOWN

CN6 & 7

CN107

CN203

(for setting) REMOTE T' STAT CDC

DIP SW RY108

CN104 CN2

RY201

TRANSFER FAN MOTION SENSOR DOOR SWITCH ROOM ID. COIL OD. COIL OUTDOOR HEATER

CONTROL CIRCUIT

CN5

RY107 RY106 RY105 RY104 RY103

MAIN BOARD UNIT

INTERFACE

CN1

RY102 RY101 RY109

50

(OPTIONAL)

COMPRESSOR

RD

ROOM

GY RD GR WH

Suggested Bid Form Specifications

The following are suggested specifications for the Zoneline 2500 Series Packaged Terminal Air Conditioner, the 3500 series Packaged Terminal Heat Pump and the 5500 series Packaged Terminal Heat Pump. The contractor will furnish Packaged Terminal Air Conditioners of the sizes and capacities shown on the schedule and in the specifications. The units shall be located as shown on the drawings and each shall consist of a chassis, room cabinet, wall case, sub-base if specified, and outdoor grille. Units shall be listed by UL, and ARI and cUL certified as to capacity and efficiency and shall be GE Zoneline® models or equal. Unit dimensions shall not exceed 42 1/8" wide and 16 1/4" high with room cabinet in place. Units shall be designed to operate on _______ volts, 60 Hz., single phase power. Chassis. Air conditioner chassis shall be the standard product of the manufacturer and shall be shipped in protective cartons to prevent damage. Cartons shall be appropriately marked at the factory with wording sufficient to warn handlers against improper stacking, up-ending, rolling or dropping. Chassis shall be slide-in type, ready to operate after installation. Each shall consist of the following sections and components: Each unit shall have a matching, easily removable, textured finish, wrap-around room cabinet molded of high temperature styrene to resist corrosion and damage. Room cabinet shall have slide-out washable filters accessible without requiring removal of room cabinet from chassis; Hermetically-sealed refrigerant system with external vibration isolated rotary-type compressor, condenser and evaporator coils and capillary refrigerant control. Cooling shall be possible to outdoor temperature of 35°F. without damage to the compressor. Airflow system consisting of one permanently lubricated two-speed fan motor for the outdoor fan and a separate permanently lubricated two-speed fan motor for the indoor fan. Outdoor fan shall be multi-blade axial-flow design made of non-corrosive material. Indoor fan shall be of a design to optimize air flow and operating sound. All motors on the exterior side of the weather barrier shall be of an enclosed design to reduce the effects of moisture and corrosion. Unit shall have a resistance heater to provide specified heat output; A fan cycle switch to permit continuous fan operation or fan cycle operation, independently selectable for heating and cooling operation; A positive cooling condensate disposal system which meets the test requirements of applicable A.R.I. Standard 310-93 (for Packaged Terminal Air Conditioners) and 380-93 (for Packaged Terminal Heat Pump). (80°F. dry bulb, 75°F. wet bulb, 80% relative humidity). Condenser and evaporator coils to be constructed of copper tubing and aluminum plate fins with enhancements necessary to achieve EER and COP rating of the unit; Indoor and outdoor airflows that match the capacity of the coils for efficient heat transfer. Water blow-off shall not occur on the indoor coil; Adjustable indoor discharge air louvers that provide a 50° off vertical air pattern with an alternate position to provide a 40° off vertical air pattern; Easily accessible controls for selection of unit Operation and Thermostat setting. Controls shall be covered by a hinged door; Air discharge area accessible for cleaning without tools when room front is removed; Positive-closing fresh air vent, with vent door secured for shipping, and optional securing in the closed position, with a concealed manual control; Solid state thermostat control to sense room temperature; Electronic temperature limiting with seven independent heating and cooling settings to limit maximum and minimum temperatures without restricting movement of thermostat control knob; Freeze SentinelTM to automatically activate the electric resistance heater and fan motor to warm and circulate indoor air to help prevent damage due to freezing temperatures. Freeze SentinelTM shall operate as long as unit is connected to powered electrical circuit and unit shall provide ability for owner to defeat the Freeze Sentinel operation; Compatible with 2 wire Central Desk Control systems; Remote Thermostat compatibility with Class 2 remote thermostat; Connections to interface with a transfer fan to move air into another room; Connections to interface with occupancy sensors; Unit shall have means of electrical connection listed by Underwriters Laboratories and compatible with the unit's required voltage and ampacity in conformance with National Electrical Code® (NEC) and local codes. Additional specifications for GE Zoneline 2500 Series Packaged Terminal Air Conditioner with Dry Air 25 Unit shall be equipped with factory installed heat pipe around evaporator coil to increase dehumidification by at least 25% over other non-heat pipe Zoneline units. Unit must be certified by ARI for capacity and dehumidification. Heat pipe system must be separate from the sealed refrigerating system of the unit.

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Additional specifications for GE Zoneline 3500 Series Packaged Terminal Heat Pump (for 5500 series units use specifications noted for 5500 series instead of these specifications). Heat pump units shall automatically change from heat pump operation to electric resistance heat when heat pump operation is unable to produce sufficient heat to maintain room temperature within 2.7°F. of thermostat set point, or when the outdoor coil temperature falls below 9°F. approximately 25°F. outdoor temperature. Heat pump unit shall automatically begin a passive defrost cycle when the outdoor coil temperature drops below 9°F. Defrosting shall be accomplished by natural defrost with unit automatically reinitiating heat pump operation when outdoor coil reaches 37°F. Unit shall be equipped with a temperature activated drain valve to allow water generated in heat pump operation and defrost cycles to drain into wall case rather than being deposited on outdoor coil. Each time the heat mode is selected, or the unit is powered up in the heat mode selection, the heat pump will use electric resistance heat to bring room temperature to selected thermostat set point. Heat pump operation will be used on subsequent unit heating operation if the room temperature is within 2.7°F of the set point and the unit is not in the defrost cycle. Unit shall have a switch concealed from room occupant to allow heat pump operation to be overridden and heat provided by electric resistance heat regardless of outdoor temperature. In the event of compressor failure during heat pump operation, unit shall automatically switch to electric resistance heat to maintain selected room temperature regardless of outdoor temperatures. Alternate specifications for GE Zoneline 5500 Series Packaged Terminal Heat Pump (for 3500 series units use specifications noted for 3500 series instead of these specifications). Heat pump units shall provide operation that will either: A) automatically phase in partial electric resistance heat, if outdoor temperature is below 46°F., simultaneously with heat pump if heat pump alone is unable to maintain room temperature; or B) use partial electric resistance heat simultaneous with heat pump operation any time the outdoor temperature is below 45°F. Selection of A or B operation is made by means of a selector switch concealed from room occupant. In either A or B operation the unit will switch to full resistance heat if room temperature continues to decline or the outdoor temperature falls below 25°F. If the outdoor temperature is above 46°F., unit will lock out electric resistance heat and operate on heat pump only.

Heat pump unit shall include Reverse Cycle Defrost that automatically begins a defrost cycle when microprocessor determines criteria for defrosting has been met. Defrosting shall be accomplished by systematically ceasing heat pump operation, pausing to allow internal refrigerant pressures to equalize, then operating the compressor with the flow of refrigerant reversed, to allow the hot gas to flow through the outdoor coil melting the accumulated frost. Unit shall automatically resume heat pump operation, after pausing to allow refrigerant pressures to equalize, at conclusion of defrost cycle. Unit shall be equipped with a temperature activated drain valve to allow water generated in heat pump operation and defrost cycles to drain into wall case rather than being deposited on outdoor coil. Each time the heat mode is selected, or the unit is powered up in the heat mode selection, the heat pump will use electric resistance heat to bring room temperature to selected thermostat set point. Heat pump operation will be used on subsequent unit heating operation if the room temperature is within 2.7°F of the set point and the unit is not in the defrost cycle. Unit shall have a switch concealed from room occupant to allow heat pump operation to be overridden and heat provided by electric resistance heat regardless of outdoor temperature. In the event of compressor failure during heat pump operation, unit shall automatically switch to electric resistance heat to maintain selected room temperature regardless of outdoor temperatures. Specifications for Optional Internal Condensate Removal (ICR) system for Zoneline 3500 or 5500 series heat pump units. Unit shall have a factory installed Internal Condensate Removal (ICR) system to permit unit to automatically dispose of heat pump generated condensate water with no overflow to outdoors to occur during heating under outdoor ambient of 55°F. Dry Bulb, 90% Relative Humidity; indoor ambient 70°F. Dry Bulb, 52% Relative Humidity, for four hours of continuous run time.

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Wall Cases and Grilles are needed for new installations Alternate specification for steel wall case. Wall case shall be constructed of heavy gauge, zinc-coated, phosphated steel, insulated and shall have a protective baked-on enamel finish. Bottom critical points of the steel wall case shall be treated with petroleum microcrystalline wax for added corrosion protection and shall meet ASTM B-117, 1800 hour hot air aerated salt spray test. Alternate specification for molded wall case. Wall case shall be constructed of a non-corroding fiberglass reinforced polyester compound. Cases shall be installed through exterior walls where shown on the plans and shall be installed per manufacturer's installation instructions. In no instance shall fasteners be used through the bottom in order to retain the water integrity of the bottom of the wall case. Outside weather panels shipped with the cases shall remain in place until the outdoor air louvers and chassis are installed, at which time they are to be removed and discarded by the installer. Outside Grille. Each unit shall be equipped with a standard exterior grille that has been designed to allow unit operation in high ambient conditions. Grilles shall be of material and design specified. Special grilles or customer louver sections to be supplied by others will conform to minimum free area requirements for unit performance and shall be submitted to the PTAC/PTHP manufacturer, if requested, for feasibility and airflow characteristics. Specifications for Sub-base (if required). Sub-Base. Each unit shall have a field installed UL listed electrical sub-base. The sub-base shall be attached to the lower inside flange of the wall case prior to installation in the exterior wall and shall include adjustable screws at the bottom corners to permit exact leveling of the wall case. The sub-base shall have a factory installed receptacle to allow unit line cord to plug into mating receptacle and shall have a chaseway to contain and conceal the line cord. The subbase shall have side panels adjustable from a minimum of 2 3/8" to a maximum of 13 3/4" to enclose the area under the wall case.

Weather Resistance. Complete unit including outside louver shall be submitted to an independent agency for weather resistance and water infiltration tests. Air infiltration test to be conducted in accordance with ASTM E283-91. With static air pressure differential of 1.57 lb./ft.2 (.3" H2O) equivalent to 25 mph wind, allowable air infiltration shall not exceed 7 ft.3/min. Water infiltration test to be conducted in accordance with ASTM E331-86 with static air pressure differential of 10.0 lb./ft2 (1.93" water) equivalent to 63 mph wind, 5.0 gal./ft.2 (8" rain/ft.2/hr.) for 15 minutes and there shall be no leakage into the room. Approvals. Units shall be certified under the ARI and cUL certification program and listed by UL. Service. Submit complete information with bid covering service availability, to whom service on units will be assigned, complete address and phone number, including phone number of emergency service personnel. Start-Up, Adjust, Demonstrate. Contractor shall be responsible for the initial starting of units, adjustments thereto, etc., to place the units in required operating condition. Contractor shall demonstrate to the owner, or his representative, the operation of units for both summer and winter functions. Warranty. The warranty shall be a full one year parts and labor on entire unit plus an additional full four years parts and labor for the sealed refrigerating system, including service call for diagnosis, and transportation to and from service shop, if necessary, at no charge to customer. The warranty shall also include a limited 2nd thru 5th year parts only warranty for fan motors, switches, thermostat, heater, heater protectors, compressor overload, solenoids, circuit boards, auxiliary controls, thermistors, frost controls, ICR pump, capacitors, varistors, and indoor blower bearing. Installation Responsibility. Units shall be installed according to the manufacturer's recommendations and the manufacturer shall not be responsible for unit failure as a result of improper installation, or unit performance when installed with accessories not approved by the manufacturer.

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Zoneline® Chassis Nomenclature

The Zoneline chassis is identified by a model number defining the type of unit, cooling capacity, electrical information and optional features included on the unit. When specifying or ordering the Zoneline chassis the use of this nomenclature will assure receiving the correct unit.

Example

A A Z Z 2 5 5 5 E H 0 1 9 2 E D 4 A P D

Zoneline®

Packaged Terminal Chassis

Special Features

B - Base Unit C - Corrosion Treated D - Internal Condensate Removal (ICR) System (Heat Pump Models Only) P - Dry Air 25

Chassis Series

25 - Deluxe Line Cool/Electric Heat 35 - Deluxe Line Heat Pump

5500 Universal Power Connection

55 - Premium Line Heat Pump (see Premium Series Models - see page 53)

Unit Type

E - Cooling with Electric Resistance Heat H - Heat Pump with Electric Resistance Heat

2500, Dry Air 25 & 3500 Numeric Designator of Heater Size

(see Heater Table Below)

Nominal Cooling Capacity

07 - 7,000 BTUH Cooling 09 - 9,000 BTUH Cooling 12 - 12,000 BTUH Cooling 15 - 15,000 BTUH Cooling Heater Table

Heater Voltage 230/208 230/208 230/208 265 265 265 Heater Amps 11.1/10.0 15.0/13.6 21.7/19.7 9.6 14.0 18.9 Designator 2 3 5 3 4 5

Voltage/Phase/Frequency

D - 230/208 Volt E - 265 Volt Single Phase 60 Hz Single Phase 60 Hz

Deluxe Line: 2500, Dry Air 25 & 3500 Series Models are manufactured with fixed heater wattages with the appropriate power cord attached (all 265 volt models are permanently connected). 5.0 KW heaters are not available on 7,000 BTUH models.

Watts 2550/2090 3450/2820 5000/4090 2550 3700 5000

Minimum KWH 2.55/2.09 3.45/2.82 5.00/4.09 2.55 3.7 5.0

Ampacity 15 20 30 15 20 30

BTUH 8,600/7,100 11,700/9,600 17,000/13,900 8,600 12,600 17,000

Deluxe Series - Cooling & Electric Heat

230/208V Models

Capacity Cooling BTUH EER (BTU/Watt) Dehumidification Pts/Hr Sensible Heat Ratio @ 230 Volts CFM, Indoor Fan High CFM, Indoor Fan Low Vent CFM Power/Ratings Power Factor Watts Amperes, F.L. Amperes, L.R. Weight (Net/Ship)** Sound Transmission Class (STC) AZ25E07D 7,100/6,900 11.8/11.8 1.7 75% 240 210 40/35 95 600/585 2.8/3.0 19.0 92/108 28 2500 Series Units AZ25E09D AZ25E12D 9,000/8,800 11.5/11.5 2.7 68% 260 230 65/60 96 785/765 3.6/3.9 21.0 93/109 28 11,700/11,500 10.9/10.9 3.6 67% 270 240 70/65 97 1075/1055 4.9/5.3 33.0 101/117 28 AZ25E12E 11,700 10.9 3.6 67% 270 240 70 94 1075 4.4 24.0 101/117 28 AZ25E15D 14,600/14,300 9.6/9.6 4.5 67% 310 280 70/65 94 1520/1490 7.0/7.5 38.0 111/127 28 AZ25E15E 14,600 9.6 4.5 67% 310 280 70 96 1520 6.0 31.0 111/127 28

Dry Air 25

AZ25E07D*P 6,800/6,600 11.1/11.1 2.2 66% 230 200 40/35 95 600/585 2.8/3.0 19.0 98/114 28 AZ25E07E*P 6,800 11.1 2.2 66% 230 200 40 96 600 2.4 16.0 98/114 28 Dry Air 25 AZ25E09D*P 8,600/8,400 10.8/10.8 3.4 58% 230 200 65/60 96 785/765 3.6/3.9 21.0 99/115 28 AZ25E09E*P 8,600 10.8 3.4 58% 230 200 65 94 785 3.2 18.0 99/115 28 AZ25E12D*P 11,200/11,000 10.2/10.2 4.5 57% 240 210 70/65 97 1075/1055 4.9/5.3 33.0 107/123 28 AZ25E12E*P 11,200 10.2 4.5 57% 240 210 70 94 1075 4.4 24.0 107/123 28

AZ25E07E AZ25E09E Capacity Cooling BTUH 7,100 9,000 EER (BTU/Watt) 11.8 11.5 Dehumidification Pts/Hr 1.7 2.7 Sensible Heat Ratio @ 265 Volts 75% 68% CFM, Indoor Fan High 240 260 CFM, Indoor Fan Low 210 230 Vent CFM 40 65 Power/Ratings Power Factor 96 94 Watts 600 785 Amperes, F.L. 2.4 3.2 Amperes, L.R. 16.0 18.0 Weight (Net/Ship)** 92/108 93/109 Sound Transmission Class (STC) 28 28 *For Dry Air 25 model number, designate respective heater number using chart above, followed by the letter "P". ** ICR adds 3 pounds to unit weight

265V Models

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Receptacles/Sub-Bases

Premium Line: 5500 Series - Power Connection Kits are

REQUIRED on Premium Zoneline Chassis. (see chart below) The correct kit for the installation is determined by the voltage and amperage of the electrical circuit and the means of connecting the unit to the building wiring. If the unit is to be plugged into a receptacle, a line cord kit would be used; if the unit is to be permanently connected, a permanent connection kit would be used. 265 volt cord set units must be installed in compliance with National Electrical Code.® Power Connection Kits - Required on premium models. See specification sheet for heater KW and branch circuit ampacity.

Tandem 230/208V 15 Amp NEMA6-20R

Perpendicular 230/208V 20 Amp NEMA6-20R

Large Tandem 230/208V 30 Amp NEMA6-30R

265V 15 Amp NEMA7-15R; receptacle used on 265V sub-base

265V 20 Amp NEMA7-20R; receptacle used on 265V sub-base

265V 30 Amp NEMA7-30R; receptacle used on 265V sub-base

Sub-bases

RAK204U RAK204D20 RAK204D30 RAK204E15 Voltage N/A 230/208 230/208 265 Amps N/A 15/20 30 15 Receptacle N/A NEMA6-20R NEMA6-30R NEMA7-15R 265 Volt units are to be direct connected. Cordset through enclosed chaseway into interior sub-base receptacle meets the NEC requirements. RAK204E20 265 20 NEMA7-20R RAK204E30 265 30 NEMA7-30R

RAK3152/3202/3302 230/208 volt Line Cord Connection Kit

230/208 Volt

Power Connection Kit Heater KW Watts BTUH Amps Min. Circuit Amps Recommended Protective Device RAK3152

Line Cord Connected Units

RAK3202 3.45/2.82 3,450/2,820 11,700/9,600 15.0/13.6 20 20 Amp Time Delay Fuse or Breaker RAK3302 5.00/4.09 5,000/4,090 17,000/13,900 21.7/19.7 30 30 Amp Time Delay Fuse or Breaker

265 Volt

RAK5152 1.7 1,700 5,800 6.4 15 15 Amp Time Delay Fuse

Permanent Connected Units** (Cord Set)

RAK5172 3.0 3,000 10,200 11.3 15 15 Amp Time Delay Fuse RAK5202 3.7 3,700 12,600 14.0 20 20 Amp Time Delay Fuse RAK5302 5.0 5,000 17,000 18.9 30 30 Amp Time Delay Fuse

2.55/2.09 2,550/2,090 8,600/7,100 11.0/10.0 15 15 Amp Time Delay Fuse or Breaker

Deluxe Series - Heat Pump Units

230/208V Models Capacity Cooling BTUH EER (BTU/Watt) Dehumidification Pts/Hr Sensible Heat Ratio @ 230 Volts CFM, Indoor Fan High CFM, Indoor Fan Low Vent CFM Power/Ratings Power Factor Watts Amperes, F.L. Amperes, L.R. Reverse Cycle Heat BTUH COP Watts Amps Weight (Net/Ship)** Sound Transmission Class (STC) 265V Models Capacity Cooling BTUH EER (BTU/Watt) Dehumidification Pts/Hr Sensible Heat Ratio @ 265 Volts CFM, Indoor Fan High CFM, Indoor Fan Low Vent CFM Power/Ratings Power Factor Watts Amperes, F.L. Amperes, L.R. Reverse Cycle Heat BTUH COP Watts Amps Weight (Net/Ship)** Sound Transmission Class (STC) ** ICR adds 3 pounds to unit weight AZ35H07D 7,100/6,900 11.8/11.8 1.7 75% 250 220 40/35 95 600/585 2.8/3.0 19.0 6400/6200 3.5/3.5 535/520 2.4/2.6 96/112 28 AZ35H07E 7,100 11.8 1.7 75% 250 220 40 96 600 2.4 16.0 6,400 3.5 535 2.2 96/112 28 3500 Series Units AZ35H09D AZ35H12D 9,000/8,800 11.5/11.5 2.7 68% 260 230 65/60 96 785/765 3.6/3.9 21.0 8400/8200 3.5/3.5 705/685 3.1/3.4 99/115 28 AZ35H09E 9,000 11.5 2.7 68% 260 230 65 94 785 3.2 18.0 8,400 3.5 700 2.8 99/115 28 11,700/11,500 10.9/10.9 3.6 67% 280 250 70/65 97 1075/1055 4.9/5.3 33.0 10900/10700 3.3/3.3 970/950 4.3/4.7 111/127 28 AZ35H12E 11,700 10.9 3.6 67% 280 250 70 94 1075 4.4 24.0 10,900 3.3 970 3.9 111/127 28 AZ35H15D 14,600/14,300 9.6/9.6 4.5 67% 310 280 70/65 94 1520/1490 7.0/7.5 38.0 13400/13200 3.1/3.1 1265/1250 5.8/6.3 121/137 28 AZ35H15E 14,600 9.6 4.5 67% 310 280 70 96 1520 6.0 31.0 13,400 3.1 1265 5.0 121/137 28

Premium Series - Heat Pump Units

AZ55H07D 7,100/6,800 12.0/12.0 1.7 75% 240 220 40/35 95 590/565 2.7/2.9 19.0 6,400/6,200 3.5/3.5 535/520 2.4/2.6 101/117 28 AZ55H07E 7,100 12.0 1.7 75% 240 220 40 96 590 2.3 16.0 6,400 3.5 535 2.2 101/117 28 5500 Series Units AZ55H09D AZ55H12D 9,000/8,800 11.5/11.5 2.8 67% 290 270 65/60 96 785/765 3.6/3.9 21.0 8,400/8,200 3.5/3.5 705/685 3.1/3.3 106/122 28 AZ55H09E 9,000 11.5 2.8 67% 290 270 65 94 785 3.2 18.0 8,400 3.5 705 2.8 106/122 28 11,800/11,600 10.9/10.9 3.6 68% 330 310 70/65 94 1085/1065 5.1/5.5 33.0 10,900/10,700 3.3/3.3 970/950 4.3/4.7 116/132 28 AZ55H12E 11,800 10.9 3.6 68% 330 310 70 94 1085 4.5 24.0 10,900 3.3 970 3.9 116/132 28 AZ55H15D 14,700/14,400 10.0/10.0 4.8 65% 350 330 70/65 95 1470/1440 6.7/7.3 38.0 13,400/13,200 3.1/3.1 1,265/1,250 5.8/6.3 123/139 28 AZ55H15E 14,700 10.0 4.8 65% 350 330 70 96 1470 5.8 31.0 13,400 3.1 1,265 5.0 123/139 28

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Complete Accessory List

Kit Number RAA62A RAB71 RAB7116 RAB7124 RAB7128 RAB7131 RAB77 RAD10 RAF452A RAG60 RAG61 RAG62 RAG63 RAG64 RAG65 RAG66 RAG67 RAK40 RAK147 RAK147D1 RAK147P1 RAK163A1 RAK163D1 RAK163P1 RAK201 RAK240D20 RAK204D30 RAK204E15 RAK204E20 RAK204E30 RAK204U RAK205CW RAK3152 RAK3202 RAK3302 RAK4002A RAK4002B RAK4002CW RAK5152 RAK5172 RAK5202 RAK5302 RAK601 RAK602 RAK6052 RAK7012 RAK7022 RAK8022 RAK806 RAK901L Description For Additional Information Refer to Page Spare filters for AZ25, AZ35, and AZ55 Models (10 per box) 10 Steel Wall Case - 13 3/4" deep 22 Steel Wall Case - 16" deep 22 Steel Wall Case - 24" deep 22 Steel Wall Case - 28" deep 22 Steel Wall Case - 31" deep 22 Molded Wall Case 22 Interior/Exterior Drain kit 35 Room Front Grille for AZ25, AZ35, and AZ55 Models 7 Stamped Aluminum Exterior Grille 39 Architectural Exterior Grille, Beige Molded Durable Polycarbonate 39 Architectural Exterior Grille, Maple Molded Durable Polycarbonate 39 Architectural Exterior Grille, Bittersweet Chocolate Molded Durable Polycarbonate 39 Architectural Exterior Grille w/Flange, Beige Molded Durable Polycarbonate 39 Architectural Exterior Grille w/Flange, Maple Molded Durable Polycarbonate 39 Architectural Exterior Grille w/Flange, Bittersweet Chocolate Molded Durable Polycarbonat 39 Aluminum Architectural Grille (Custom Colors Available by Special Order) 39 Condenser Air Deflector Kit 21 Wall Thermostat For Heat Pump Models - Mechanical 16 Wall Thermostat For Heat Pump Models - Electronic Digital 16 Wall Thermostat For Heat Pump Models - Electronic Digital Programmable 16 Wall Thermostat For Resistance Heat Models - Mechanical 15 Wall Thermostat For Resistance Heat Models - Electronic Digital 15 Wall Thermostat For Resistance Heat Models - Electronic Digital Programmable 15 Sub-base Cover Plate with Knockouts 43 Sub-base - 208/230 Volt with NEMA 6-20R 15/20 Amp Receptacle -Chaseway Included 23 Sub-base - 208/230 Volt with NEMA 6-30R 30 Amp Receptacle -Chaseway Included 23 Sub-base - 265 Volt with NEMA 7-15R 15 Amp Receptacle - Chaseway Included 23 Sub-base - 265 Volt with NEMA 7-20R 20 Amp Receptacle - Chaseway Included 23 Sub-base - 265 Volt with NEMA 7-30R 30 Amp Receptacle - Chaseway Included 23 Sub-base - non-electrical Chaseway not Included 23 Chaseway for Sub-base 41 Universal Power Cord - 5500 series - 15 Amp 230/208 V - 2.55/2.09 kW heat 41 Universal Power Cord - 5500 series - 20 Amp 230/208 V - 3.45/2.82 kW heat 41 Universal Power Cord - 5500 series - 30 Amp 230/208 V - 5.0/4.09 kW heat 42 Direct Connect Junction Box - 230/208 Volts for use with AZ25 or AZ35 41 Direct Connect Junction Box - 230/208 Volts for use with AZ55 Models 42 Wiring Harness w/In-Line Connector - Adapt Line Cord to Direct Connection 41 Universal Power Cord - 5500 series - 265 V / 15 Amp - Use w/RAK204E15 Sub-base - 1.7 kW heat 42 Universal Power Cord - 5500 series - 265 V - 15 Amp - Use w/RAK204E15 Sub-base - 3.0 kW heat 42 Universal Power Cord - 5500 series - 265 V - 20 Amp - Use w/RAK204E20 Sub-base - 3.7 kW heat 42 Universal Power Cord - 5500 series - 265 V - 30 Amp - Use w/RAK204E30 Sub-base - 5.0 kW heat 42 Duct extension - Insulated - 44" long - includes Register and Mounting Flange 37 Register and Trim Flange (Included with RAK601) 37 Duct Adapter for New Installation (or Older non-GE Duct Adapter Installation) 37 Duct Transition for 2500/3500 Replacing Existing Chassis (Original Installation Pre-1988) 37 Duct Transition for 2500/3500 Replacing Existing Chassis (1988 - 1998 Original Installation) 37 Locking Door Kit 11 Control Panel Cover (for use with remote thermostat) 15 Wall Case Insulation Kit 23

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General Installation Suggestions

Many times poor or non-existent caulking around the exterior of the wall case results in air infiltration causing the unit to run excessively. One way to check for air infiltration is to look under and around the unit to the outdoors. If you can see light, there is air infiltration. The first floor of a building is where this problem most frequently occurs since caulking the bottom of the wall case may require lying outside in the dirt while working. This has been the cause of many complaints about the "short cycling" of the Freeze SentinelTM. Curtains, furniture or other obstructions interfering with the discharge air circulation will make the unit cycle turn off too soon since the cooled (or heated) discharge air is pulled back into the unit. This results in a room that is not adequately heated or cooled. Blocking the discharge air on the left side during heating operation can result in the air getting hot enough to distort the plastic room front. If you have a property where this may occur we recommend a "tent card" advising room occupants not to put anything on the unit. Consult the electrical inspector early in the project, especially if the power to the air conditioner is to be 265 volts, to understand what is required to comply with local electrical codes.

Wall Case/Exterior Grille

When making an installation where the exterior grille is flush with the exterior wall, or part of a custom window/louver section, make sure the installer caulks the wall case to the exterior wall, especially the bottom of the case. Many times the air conditioners are run during construction and the building is not closed. This can result in excessive humidity from the warm humid air entering the building, or the "drying out" of the building materials. Many problems have been caused by condensate water or rainwater running back into the building where proper caulking has not been done.

Capacity Considerations

A unit that has a greater cooling capacity than required will cool the room quickly but will usually not run long enough under normal operation to adequately dehumidify the room. Most musty odors in rooms are due to excess humidity. Using a smaller capacity unit or using Dry Air 25 units will provide better dehumidification. The largest factor in causing mold and mildew in the room is excess moisture, and a smaller unit running longer or a Dry Air 25 model can remove more moisture. Mold behind wall coverings that do not allow water vapor to pass through - vinyl wallpaper or oil base paints, for example - is not a problem of excessive moisture in the room, but rather is caused by moisture trapped in the walls. Using a resistance heater larger than required - using a 5 kW heater when a 3.45 kW heater would suffice for example may not cost any more in electrical consumption since the larger heater will operate for less time. The "Demand Charge" portion of the utility bill - which is based on the highest electrical load for a period of time - may be a significant portion of the utility bill. Some customers have reported the "Demand Charge" actually being more than the usage charge. In a 100 room property it would be possible for the demand of the 5.0 kW heater versus a 3.45 kW heater to be 155 kW more than the demand charge if the lower wattage heaters were used. Working with the utility companies to understand their method of billing and taking advantage of any rebates they may offer can reduce the utility bill.

Electrical Wiring Installation

Do not allow the installer to drill a hole in the wall case to run the electrical wiring. If this is done, the wiring will have to be run between the chassis and the edge of the wall case so it can be connected to the unit wiring on the room side of the wall case. When the chassis is removed for servicing or cleaning, the insulation on the wires can be cut and can create a safety hazard. If the electrical connection on a 230 volt or 208 volt installation is to be made by the line cord plugged into a wall mounted receptacle, the receptacle should be located in the wall under the case or close to the side of the wall case. This installation makes a much neater appearance than a line cord running a foot or more across the floor. The electrician may want to place the receptacle as far from the unit as possible to save a few feet of wiring without considering how the installation may appear.

Central Desk Control and Remote Thermostat Wiring

Do not allow the installer to drill a hole in the wall case to run Central Desk Control wiring or remote thermostat wiring to the unit terminals. CDC and remote thermostat wiring is classified as low voltage wiring and does not have to be run in conduit unless required by local code. CDC and remote thermostat wiring should be run in the walls and exit the wall under the wall case about 2" from the right hand side. The base pan is designed with a clearance for the line cord and the low voltage wiring can be run to the chassis in this area also. Wire molding can be used to hold the wiring close to the bottom of the wall case. If a sub-base is used, the wiring can be run through the sub-base, entering the rear and exiting through one of the front panels. When the room cabinet is in place the CDC or remote thermostat wiring is usually not visible to someone standing or sitting in the room. Do not run the low voltage wiring in conduits with line voltage wiring or near uninsulated line voltage wiring since induced current can interrupt the low voltage controls.

Exterior Grilles

When replacing an older unit the existing outdoor grille may need to be changed or modified. Outdoor air flow patterns have changed and this may dictate the need for outdoor grille replacement or modification.

57

Ducted Installation Comments

New Installations The GE Zoneline 2500 and 3500 series are approved for ducted installation using the GE Duct Adapter model RAK6052 and the GE Duct Extension RAK601. A field fabricated duct extension with the same interior measurements as the RAK601 may be used with the RAK6052 duct adapter. GE does not recommend ducting in more than one direction. The use of a duct adapter other than the RAK6052 is not approved by GE and may cause problems such as inadequate airflow to the secondary room or the unit shutting off on one of the overload devices. Failure to allow for adequate air return from the secondary room is often the cause of less than satisfactory performance of a ducted installation. Replacement Installations GE offers duct adapters to allow for easy replacements of previous design chassis in ducted installations where a GE duct adapter was used in the original installation. A duct adapter is available that will align with the duct extension when GE built components were used in the original installation. The duct extension used from the early 1960's until late 1987 was 8-3/8" high by 6-1/2" wide. If the chassis to be replaced is the flat-top discharge (design until late 1987) the duct adapter model RAK7012 will align with the existing duct extension. This means the duct extension will not have to be changed. However, to keep the cost of the replacement to a minimum there are components that will need to be taken off the existing installation and used on the RAK7012 duct adapter. The wall case mounting brackets, screws, discharge grille, damper, and end cap will need to be retained. If the chassis is a slope-front discharge and the duct dimensions are 8-3/8" high by 6-1/2" wide then the chassis has already been replaced and the purchase of a new duct adapter is not required. The only piece that needs to be replaced in this installation is the transition piece, model RAK7022, which fits between the chassis and the duct adapter. If the chassis being replaced has a model number that begins with AZ22E or AZ32H the new 2500 or 3500 series unit can be installed using the same components that were used for the 2200 or 3200 series unit. If the chassis is a slope-front discharge and the duct dimensions are 7-3/32" high by 6-1/2" wide only the RAK7022 transition piece is required to install a 2500 or 3500 series unit in the ducted installation. There were a number of Zoneline units installed in ducted installations that did not use a GE duct adapter. The easiest way to determine if the existing duct adapter is a GE duct adapter is to compare the duct adapter dimensions to the dimensions above. If the dimensions are different than the dimensions above or it the duct adapter is not made of sheet metal, it is not a GE duct adapter. In such installations GE recommends the removal of the old duct adapter and duct extension and the installation of a RAK6052 duct adapter and a RAK601 duct extension. Zoneline units installed in installations not using GE duct adapters and an extension with the same cross-section dimensions as the duct adapter may not be covered by the warranty.

58

Alphabetical Index

Category Page No.

Accessory List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Application Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Auxiliary Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Case Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Central Desk Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Condensate Disposal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 36 Cooling/Heat Pump Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Ducted Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 39 Dry Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 43 Exterior Grilles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 Features Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 58 Heat Pumps - Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20 Introduction to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Introduction to Zoneline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Latent System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Maximum Connected Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Mini-Specs 2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Mini-Specs 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Mini-Specs 5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Multiple Unit Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Normal Yearly Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Remote Thermostat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 50 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 55 Suggested Big Form Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - 53 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wall Case/Sub Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - 33 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Zoneline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

59

ZONELINE WARRANTY

WHAT IS COVERED

FULL ONE-YEAR WARRANTY

Staple sales slip or cancelled check here. Proof of original purchase date is needed to obtain service under warranty. For service in the U.S., call 800-GE-CARES. In Canada, contact: Manager, Consumer Relations, Camco Inc., 5800 Keaton Crescent, Mississauga, Ontario, Canada L5R 3K2.

LIMITED 2ND THROUGH 5TH YEAR PARTS WARRANTY

For the second through the fifth year from date of original purchase, General Electric will provide, free of charge, parts that fail as a result of a manufacturing defect. Parts covered are fan motors, switches, thermostat, heater, heater protectors, compressor overload, solenoids, circuit boards, auxiliary controls, thermistors, frost controls, ICR pump, capacitors, varistors, and indoor blower bearing. This is a limited parts-only warranty, and does not include labor or transportation to and from the service shop.

For one year from date of original purchase, we will provide, free of charge, parts and service labor on site to repair or replace any part of the Zoneline unit that fails because of a manufacturing defect.

FULL FIVE-YEAR SEALED REFRIGERATING SYSTEM WARRANTY

For five years from the date of original purchase, we will provide, free of charge, parts and on-site service labor to repair or replace any part of the sealed refrigerating system (the compressor, condenser, evaporator and all connecting tubing) that fails because of a manufacturing defect. WHAT IS NOT COVERED · Service trips to your site to teach you how to use the product. · Improper installation. If you have an installation problem, or if the air conditioner is of improper cooling capacity for the intended use, contact your dealer or installer. You are responsible for providing adequate electrical connecting facilities. · Replacement of fuses or resetting of circuit breakers. · In commercial locations, labor necessary to move the unit to a location where it is accessible for service by an individual technician. · Failure of the product resulting from

modifications to the product or due to unreasonable use including failure to provide reasonable and necessary maintenance. · Failure or damage resulting from corrosion due to installation in an environment containing corrosive chemicals. · Failure or damage resulting from corrosion due to installation in a coastal environment, except for models treated with special factoryapplied anti-corrosion protection as designated in the model number. · Damage to product caused by improper power supply voltage, accident, fire, floods or acts of God. · Incidental or consequential damage to personal property caused by possible defects with this air conditioner.

Warrantor: General Electric Company. Louisville, KY 40225

This warranty is extended to the original purchaser and any succeeding owner for products purchased for use within the USA and Canada. In Alaska, the warranty excludes the cost of shipping or service calls to your site. Some states do not allow the exclusion or limitation of incidental or consequential damages. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. To know what your legal rights are in your state, consult your local or state consumer affairs office or your state's Attorney General. Equipment used as a primary source for heating or cooling is an integral part of the building in which it is installed. Proper application is essential for satisfactory performance over a wide range of operating conditions. It is strongly recommended that a professional engineer determine proper application. If this unit is a replacement unit, its specifications and performance may differ from those of the unit it is replacing. For that reason, we again strongly recommend that a professional engineer determine proper application. See page 21. GE has a policy of continuous improvement on its products and reserves the right to change materials and specifications without notice.

R

Listed by Underwriters' Laboratories.

R

R

GE Appliances

General Electric Company Louisville, Kentucky 40225 www.GEAppliances.com

Pub. No. 20-S070P OTT1719 8/01

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